Method and system for automatic control of wire and cable production

Abstract

The application relates to an automatic control method and system for wire and cable production. The method comprises: acquiring a rotation angle signal of a take-up spindle; calculating a take-up speed according to the rotation angle signal, and generating an initial tension control signal in combination with a preset tension value; decomposing the rotation angle signal into a total number of wound turns and a current winding phase angle; reading a pre-stored low-vibration phase window; determining whether the current winding phase angle falls within the low-vibration phase window; if yes, outputting an enable signal to a tension sensor, and acquiring a real-time tension value output by the tension sensor in response to the enable signal; if no, acquiring a last effective tension value; taking the real-time tension value or the last effective tension value as a current effective tension value; comparing the current effective tension value with a preset target tension value, and generating a torque control instruction according to a comparison result, and adjusting the rotation speed of the take-up spindle through the torque control instruction. The application can improve the tension control accuracy in the cable winding process.

Description

Technical Field

[0001] This application relates to the field of wire and cable manufacturing technology, and in particular to an automated control method and system for wire and cable production. Background Technology

[0002] In the continuous production of wires and cables, the take-up process is a crucial step in ensuring product quality. The stability of the take-up tension directly affects the neatness of the cable arrangement, the tightness between layers, the consistency of the outer diameter, and the subsequent unwinding performance. Excessive tension can lead to cable stretching deformation or even breakage; insufficient tension can easily cause loose take-up, edge collapse, or interlayer slippage. Therefore, high-precision and highly robust tension control is a core technical requirement for take-up equipment.

[0003] Currently, commonly used cable tension control generally adopts a closed-loop feedback structure of tension sensor + servo motor: the tension sensor detects the cable tension in real time, compares it with the target value to generate an error signal, and then outputs a torque command through PID and other control algorithms to adjust the speed of the take-up spindle to maintain constant tension.

[0004] However, during the aforementioned cable winding process, the tension sensor's measurement signal may be affected by vibration, leading to distorted tension feedback and consequently causing fluctuations or instability in tension control. Therefore, improvements are urgently needed. Summary of the Invention

[0005] Therefore, it is necessary to provide an automated control method and system for wire and cable production that achieves high-accuracy cable tension control, addressing the aforementioned technical problems.

[0006] In a first aspect, this application provides an automated control method for wire and cable production. The method includes: responding to a tension control instruction and executing a tension control process; wherein the tension control process includes the following steps: acquiring a rotation angle signal of the take-up spindle; calculating the take-up speed based on the rotation angle signal and generating an initial tension control signal in conjunction with a preset tension value; decomposing the rotation angle signal into the total number of turns wound and the current winding phase angle; wherein the current winding phase angle represents the angular position of the cable in the currently unfinished winding turn; and reading a pre-stored low-vibration phase window; wherein the window is a preset angle range. The system identifies the winding phase range that minimizes vibration interference caused by cable bending; it determines whether the current winding phase angle falls within the low-vibration phase window; if so, it outputs an enable signal to the tension sensor and acquires the real-time tension value output by the tension sensor in response to the enable signal; if not, it acquires the previously stored effective tension value; it uses the real-time tension value or the previous effective tension value as the current effective tension value; it compares the current effective tension value with the preset target tension value and generates a torque control command based on the comparison result, adjusting the rotation speed of the take-up spindle through the torque control command to control the cable take-up tension.

[0007] In one embodiment, determining whether the current winding phase angle falls within the low-vibration phase window involves: calculating the real-time winding diameter of the take-up reel based on the total number of windings, the obtained cable diameter parameters, and the initial reel diameter parameters; calculating the number of layers of cable formed on the take-up reel based on the real-time winding diameter and the preset cable laying pitch; calculating the change in the helix angle of the cable spiral path based on the real-time winding diameter and the number of layers; correcting the current winding phase angle based on the change in the helix angle to obtain the corrected current winding phase angle; and determining whether the corrected current winding phase angle falls within the low-vibration phase window. The cable laying pitch is determined based on the synchronous operation relationship between the cable laying mechanism and the take-up spindle.

[0008] In one embodiment, reading a pre-stored low-vibration phase window specifically involves: obtaining the stiffness level corresponding to the cable type; and reading the pre-stored low-vibration phase window based on the stiffness level and the real-time roll diameter.

[0009] In one embodiment, if the current winding phase angle does not fall within the low vibration phase window, the previous effective tension value is used as the current effective tension value. Specifically, based on a preset tension decay model, the current estimated tension value is calculated based on the previous effective tension value and the time interval elapsed from the acquisition time of the previous effective tension value to the current time. The tension decay model characterizes the physical characteristic that the cable tension slowly decreases over time due to the combined effects of friction of the guide roller bearing, rotational resistance of the take-up reel, and viscoelastic creep of the cable material during the period when the current winding phase angle does not fall within the low vibration phase window and the output of the tension sensor is prohibited. The current estimated tension value is used as the current effective tension value.

[0010] In one embodiment, the rotational speed of the take-up spindle is adjusted by a torque control command. Specifically, based on the current winding phase angle and the obtained number of pole pairs of the spindle drive motor, the mechanical phase interval corresponding to the commutation cycle of the spindle drive motor is calculated; a periodic compensation torque signal synchronized with the mechanical phase interval is generated; the periodic compensation torque signal is superimposed on the torque control command to obtain a compensation torque command; and the rotational speed of the take-up spindle is adjusted by the compensation torque command. The amplitude of the periodic compensation torque signal does not exceed a preset proportional threshold of the torque control command amplitude, and its phase is aligned with the mechanical phase interval to avoid phase conflict with the feedback control.

[0011] In one embodiment, after adjusting the rotational speed of the take-up spindle via torque control commands to control the take-up tension of the cable, the method further includes: when the take-up control system is in a stable tension control state, reading the q-axis current signal of the spindle drive motor; performing harmonic analysis on the q-axis current signal to calculate the total harmonic distortion (THD) content; if the THD content exceeds a preset electrical interference threshold N times consecutively and the duration exceeds a preset duration, triggering a tension control instruction to execute subsequent tension control procedures; in the subsequent tension control procedures, generating a periodic compensation torque signal synchronized with the mechanical phase interval based on the THD content; wherein N is an integer greater than or equal to 1.

[0012] In one embodiment, acquiring the real-time tension value output by the tension sensor in response to the enable signal specifically involves: acquiring the cable take-up speed; calculating the gradient time corresponding to the enable signal based on the take-up speed, the gradient time being inversely proportional to the take-up speed; during the period when the current winding phase angle enters the low-vibration phase window, controlling the enable signal to gradually rise from an invalid level to an effective level over the gradient time, and maintaining the effective level before exiting the window; when the current winding phase angle exits the low-vibration phase window, controlling the enable signal to gradually decrease from an effective level to an invalid level over the gradient time; and acquiring the real-time tension value output by the tension sensor in response to the enable signal being at an effective level.

[0013] In one embodiment, before determining whether the current winding phase angle falls within the low vibration phase window, the method further includes: determining whether the total number of winding turns has reached a preset number of turns at the end of the full disk; if it has, then reducing the window width of the pre-stored low vibration phase window to obtain a full disk phase window, and extending the gradual change time of the enable signal, wherein the extended gradual change time is not greater than a preset maximum allowable delay time; correspondingly, determining whether the current winding phase angle falls within the low vibration phase window specifically involves: determining whether the current winding phase angle falls within the full disk phase window; obtaining the real-time tension value output by the tension sensor in response to the enable signal specifically involves: obtaining the real-time tension value output by the tension sensor in response to the enable signal including the extended gradual change time.

[0014] In one embodiment, after adjusting the rotational speed of the take-up spindle via torque control commands to control the take-up tension of the cable, the method further includes: when the take-up control system is in a stable tension control state, acquiring a continuous tension signal within a complete winding turn; performing spectral analysis on the continuous tension signal to identify the phase interval with the smallest standard deviation of the tension signal as the phase interval with the lowest vibration energy; taking the intersection of the phase interval with the lowest vibration energy and the currently used phase window as the updated phase window; wherein, the currently used phase window is a low-vibration phase window or a full-coil phase window; if the updated phase window is inconsistent with the currently used phase window, triggering a tension control instruction to execute the subsequent tension control process; in the subsequent tension control process, determining whether the current winding phase angle falls within the updated phase window; wherein, if the current state is at the end of a full-coil state, the width of the updated phase window does not exceed the width of the full-coil phase window.

[0015] Secondly, this application provides an automated control system for wire and cable production. The system includes: an angle acquisition module for acquiring the rotation angle signal of the take-up spindle; a phase decomposition module for decomposing the rotation angle signal into the total number of turns wound and the current winding phase angle; wherein the current winding phase angle represents the angular position of the cable in the currently incomplete winding turn; a window reading module for reading a pre-stored low-vibration phase window; wherein the low-vibration phase window is a preset angle range corresponding to the winding phase range where the vibration interference caused by bending of the cable is minimal; a phase judgment module for judging whether the current winding phase angle falls within the low-vibration phase window; and a tension sampling control module. The system is configured to: output an enable signal to the tension sensor when the current winding phase angle falls within the low-vibration phase window, and acquire the real-time tension value output by the tension sensor in response to the enable signal; and acquire the previously stored effective tension value when the current winding phase angle does not fall within the low-vibration phase window; an effective tension determination module is configured to use the real-time tension value or the previously stored effective tension value as the current effective tension value; a torque generation module is configured to compare the current effective tension value with a preset target tension value, and generate a torque control command based on the comparison result; and a speed adjustment module is configured to adjust the speed of the take-up spindle through the torque control command to control the take-up tension of the cable.

[0016] The aforementioned automated control method and system for wire and cable production first acquires the rotation angle signal of the take-up spindle and decomposes it into the total number of turns wound and the current winding phase angle, thereby accurately identifying the instantaneous angular position of the cable in each turn. Based on this, the current phase angle is judged through a pre-stored low-vibration phase window (a specific angle range with minimal vibration interference): only when the phase angle enters this window is the tension sensor enabled and its output sampled as the real-time tension value; in the high-vibration phase range, the sensor signal is actively shielded, and the previous effective tension value is used instead. This tension signal acquisition mechanism fundamentally avoids the negative impact of vibration interference on tension feedback, ensuring high reliability of the tension data upon which the closed-loop control is based, thereby significantly improving the control accuracy and system stability of the take-up tension. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the drawings used in the description of the embodiments of this application or related technologies will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a flowchart illustrating an automated control method for wire and cable production in one embodiment.

[0019] Figure 2 This is a flowchart illustrating the step of determining whether the corrected current winding phase angle falls within the low-vibration phase window in one embodiment.

[0020] Figure 3 This is a flowchart illustrating the step of reading a pre-stored low-vibration phase window in one embodiment.

[0021] Figure 4 This is a flowchart illustrating the steps for determining the current effective tension value in one embodiment.

[0022] Figure 5 This is a flowchart illustrating the steps of adjusting the rotational speed of the take-up spindle in one embodiment.

[0023] Figure 6 This is a flowchart illustrating the steps of generating a periodic compensation torque signal synchronized with the mechanical phase interval in one embodiment.

[0024] Figure 7 This is a flowchart illustrating the steps of obtaining the real-time tension value output by the tension sensor when the response enable signal is at an effective level, as shown in one embodiment.

[0025] Figure 8This is a flowchart illustrating the step of reducing the window width of a pre-stored low-vibration phase window in one embodiment.

[0026] Figure 9 This is a flowchart illustrating the step of determining the updated phase window in one embodiment.

[0027] Figure 10 This is a block diagram of an automated control system for wire and cable production in one embodiment. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this application clearer, a detailed description will be provided below in conjunction with the accompanying drawings and embodiments. It should be noted that the embodiments described herein are for illustrative purposes only and are not intended to limit the scope of this application.

[0029] In one exemplary embodiment, an automated control method for wire and cable production is provided, which is deployed on a wire and cable take-up production line. The production line mainly consists of a pay-off frame, a tension detection unit, a take-up control system, a wire laying mechanism, and a controller.

[0030] The tension detection unit includes a weighing tension sensor mounted below the fixed guide roller, outputting a 0-10V analog signal and equipped with an enable port controlled by the controller. The take-up control system includes a permanent magnet synchronous servo motor, controlled by a matching servo driver, capable of receiving torque commands from the controller in real time and providing feedback on the motor's actual speed. An absolute multi-turn rotary encoder is installed at the end of the take-up spindle, providing high-precision rotation angle signals to the controller. The cable unfolding mechanism uses a ball screw drive, controlled by an independent stepper motor via a synchronous belt. Its pulse input is dynamically generated by the controller based on the real-time spindle speed and an electronic gear ratio, ensuring synchronization with the take-up spindle. Upon receiving a tension control instruction, the controller executes the tension control procedure.

[0031] Optionally, the tension control indication can be either a manual command triggered by the operator on the human-machine interface to start the tension control, or a control signal automatically issued by the host computer or the central control of the production line after detecting the start of the take-up process and the stable entry of the cable into the take-up path. This indication marks the start of the tension closed-loop control cycle. Optionally, this process is executed cyclically with a fixed sampling period (e.g., 1ms or 2ms), scheduled by an embedded real-time controller to ensure the real-time performance and stability of the control.

[0032] Among them, such as Figure 1 As shown, the tension control process includes the following steps S100~S800: S100, Obtain the rotation angle signal of the take-up spindle.

[0033] The rotation angle signal is provided by a high-resolution absolute encoder or incremental encoder, which is directly mounted on the unloaded end of the take-up spindle and rotates coaxially with the spindle. For example, in a certain control cycle, the encoder returns a raw angle value of 125678.34°, which will be used as the basis input for subsequent phase decomposition.

[0034] S200, decompose the rotation angle signal into the total number of turns wound and the current winding phase angle.

[0035] The current winding phase angle refers to the angular position of the cable in the current unfinished winding turn. The total number of winding turns is obtained by counting the full turns using the rotation angle signal, and the calculation formula is as follows: Furthermore, the current winding phase angle is the result of taking the rotation angle signal modulo 360°, and the calculation formula is as follows: For example, when the total angle is 125678.34°, the total number of turns is... The current winding phase angle is 278.34°. .

[0036] S300: Read the pre-stored low-vibration phase window.

[0037] The low-vibration phase window is a preset angular range, specifically referring to the winding phase range where the amplitude of mechanical vibration interference caused by the periodic bending and unbending action of the cable on the take-up reel is minimized. The periodic bending vibration originates from the microscopic deformation and recovery process of the cable as it passes the guide roller or the edge of the take-up reel, and its vibration characteristics are related to the cable's material properties, diameter, take-up speed, reel diameter, and the geometry of the take-up reel.

[0038] Optionally, this window can be pre-determined through offline testing and spectrum analysis of a specific cable type under typical take-up conditions. For example, under laboratory conditions, vibration measurements of the cable at different phase points on the take-up reel are performed using an accelerometer or laser vibrometer. Through synchronous data acquisition from a tension sensor, and using spectrum analysis techniques such as Fourier transform or wavelet analysis, the phase interval with the lowest vibration energy and smallest tension fluctuation is identified. For example, the low-vibration phase window can be set to [110.00°, 170.00°], meaning that within this 60-degree mechanical phase interval, the mechanical vibration of the cable has the least impact on tension measurement.

[0039] S400: Determine whether the current winding phase angle falls within the low vibration phase window. If yes, execute S500; otherwise, execute S600.

[0040] This judgment is achieved through numerical comparison. For example, if the current winding phase angle is 158.34° and the low vibration phase window is [110.00°, 170.00°], then 158.34°∈[110.00°, 170.00°], and the judgment result is yes; if the phase angle is 200.00°, the result is no.

[0041] S500 outputs an enable signal to the tension sensor and acquires the real-time tension value output by the tension sensor in response to the enable signal.

[0042] Optionally, the enable signal can be a digital or analog control signal used to control the enable terminal of the tension sensor's signal conditioning circuit or data acquisition module. When the enable signal is valid, the sensor output can enter the main controller's sampling channel; when invalid, the sampling channel is shielded or set to zero.

[0043] S600: Obtain the previously stored effective tension value.

[0044] The previous effective tension value refers to the tension value that was successfully acquired and verified most recently when the current winding phase angle entered the low vibration phase window. For example, if the tension value acquired in the previous turn at a phase angle of 145.2° was 50.3N, this value is the current previous effective tension value, which is used as a benchmark for tension estimation during non-window periods.

[0045] S700: Use the real-time tension value or the previous effective tension value as the current effective tension value.

[0046] Based on the judgment result of S500, one of the two data sources is selected as the tension feedback value for the current control cycle (i.e. the tension control process executed this time).

[0047] S800 compares the current effective tension value with the preset target tension value and generates a torque control command based on the comparison result. The torque control command is used to adjust the rotation speed of the take-up spindle to control the take-up tension of the cable.

[0048] The target tension value is set by process parameters (e.g., 50N), and the comparison result is the tension error. Optionally, a PID algorithm or adaptive control law (such as fuzzy PID or model predictive control) can be used to convert the error into a torque control command. For example, if the current effective tension is 48.5N and the target is 50N, the error is +1.5N. The controller outputs a positive torque increment to slightly accelerate the spindle, thereby increasing the tension to the target value. This torque command is sent to the servo driver, which drives the motor to adjust its speed in real time, achieving dynamic stabilization of the tension.

[0049] In one exemplary embodiment, such as Figure 2As shown, S500 determines whether the current winding phase angle falls within the low vibration phase window. Specifically, S501 calculates the real-time winding diameter of the take-up reel based on the total number of windings, the obtained cable diameter parameters, and the initial reel diameter parameters.

[0050] Among them, cable diameter parameters The cable outer diameter can be input by the operator through the human-machine interface or obtained in real time through online visual measurement; initial coil diameter parameter. This is the outer diameter of the take-up reel when empty; it is an inherent parameter of the equipment and is pre-stored in the controller's parameter library. Real-time reel diameter. The calculation is based on the principle of geometric superposition: for each turn of winding, the radius of the take-up reel increases by one cable diameter (single layer) or half a diameter (double-sided arrangement). Under the assumption of a tight single-layer arrangement, the real-time winding diameter calculation formula is: For example, initial disk diameter cable diameter It has already coiled up. Then the real-time volume The calculation results are used for subsequent layer and spiral path modeling and form the basis for geometric corrections.

[0051] S502. Calculate the number of layers formed on the take-up reel based on the real-time coil diameter and the preset cable pitch.

[0052] Among them, the cable pitch This refers to the center distance between two adjacent turns of the cable on the take-up reel in the axial direction, which is determined by the mechanical structure and control parameters of the cable laying mechanism (such as the ratio of lead screw to spindle speed). This parameter is calibrated and pre-stored in the controller during the equipment commissioning phase.

[0053] Effective cable width of the take-up reel Given the equipment parameters (e.g., 500mm), under an ideal close-packed arrangement, the number of coils that can be accommodated in a single layer is... Therefore, the current total number of layers. It can be obtained through integer division: For example, if the width of the ribbon cable... ribbon cable pitch Then the number of single-layer rings ;when At that time, number of floors The number of layers reflects the three-dimensional stacking characteristics of the cables on the reel.

[0054] S503. Calculate the change in helix angle of the cable spiral path based on the real-time coil diameter and number of layers.

[0055] In this process, the cable does not move in a pure circular motion on the take-up reel, but rather winds along a spiral path. The helix angle of this spiral is... Defined as the angle between the tangent of the helix and a plane perpendicular to the spindle axis, its tangent is equal to the ratio of the axial feed rate to the circumferential linear velocity. Under steady-state cabling conditions, the helix angle can be approximated as: Due to the change in roll diameter Increase, rise angle It gradually decreases. And the change in the angle of ascent... This refers to the equivalent phase shift introduced by the current winding layer relative to an ideal plane winding (rise angle of 0). This change can be converted into a correction amount for the current winding phase angle through geometric projection relationships. For example, when hour, The impact is significant when the line is being withdrawn at high speed.

[0056] S504. Based on the change in the rise angle, the current winding phase angle is corrected to obtain the corrected current winding phase angle.

[0057] Due to the presence of the helical path, there is a slight deviation between the mechanical phase of the cable's actual contact with the edge of the take-up reel or the guide roller and the geometric phase reflected by the spindle rotation angle. This deviation can be modeled as a phase lag or lead caused by the heave angle. The correction formula can be expressed as: ;in, The original current winding phase angle, To correct the phase angle, The proportionality coefficient related to the layout of the wiring mechanism (which can be obtained through calibration, for example) For example, if the original phase angle If the change in the lifting angle is equivalent to a phase shift of 0.8°, then the corrected phase angle... This correction significantly improves the accuracy of phase determination and avoids misjudgments of window assignment due to geometric errors.

[0058] S505. Determine whether the corrected current winding phase angle falls within the low vibration phase window.

[0059] For example, according to the vibration phase calibration specifications, the initial phase angle range of simple harmonic vibration is -180° to 180°. If the low vibration phase window is set to [110.00°, 170.00°], the corrected phase angle is 157.54°, and the judgment result is yes; if the uncorrected phase angle is 158.34° (still within the window), but the corrected phase angle is 171.2°, the judgment result is no, thus avoiding the mis-collection of tension data in the actual high vibration zone. This correction mechanism ensures that the low vibration window judgment is highly consistent with the physical reality, improving the anti-interference capability.

[0060] The cable laying pitch is determined based on the synchronous operation of the cable laying mechanism and the take-up spindle. Specifically, the stepper motor of the cable laying mechanism has its pulse frequency dynamically adjusted by the same central controller according to the real-time speed of the spindle, ensuring that the cable laying mechanism moves precisely one pitch for every revolution of the spindle. This synchronization can be achieved through electronic gear ratio or master-slave shaft linkage control.

[0061] In one exemplary embodiment, such as Figure 3 As shown, S300 reads the pre-stored low vibration phase window, specifically: S301, obtain the stiffness level corresponding to the cable type.

[0062] The cable type refers to the specific specifications and material composition of the wires and cables, such as copper core PVC insulated RVV2×1.5mm² cable, aluminum core cross-linked polyethylene insulated YJV3×95mm² cable, or fiber optic composite overhead ground wire OPGW, etc. Different cables exhibit significantly different bending stiffness characteristics due to differences in conductor materials (copper, aluminum, optical fiber), insulation layer materials (PVC, XLPE, silicone rubber), sheath structure (single layer, double layer, armored), and cross-sectional geometry (circular, sector-shaped, compacted).

[0063] This embodiment quantifies the bending stiffness of the cable into a discrete stiffness level parameter. This parameter is a predefined integer or enumeration value (e.g., ...). Where 1 represents an extremely flexible cable, such as a thin-diameter optical fiber, and 5 represents a high-stiffness cable, such as a large-section armored cable. This stiffness rating parameter can be obtained in any of the following ways: Method 1 (manual input): After the operator selects the cable model on the human-machine interface, the corresponding stiffness rating parameter is automatically retrieved from the pre-stored cable database; Method 2 (automatic identification): The identification information on the cable reel is read using a barcode scanner or RFID, and the central controller parses and matches the stiffness rating; Method 3 (online estimation): Based on historical tension-velocity response data, the stiffness rating is inferred in real time using a machine learning model (such as a support vector machine or neural network) (this is an optional advanced function). For example, for RVV2×0.75mm² flexible cable, its stiffness rating parameter... For YJV223×300mm² armored cables, their stiffness rating parameters... This parameter is the key basis for the subsequent dynamic selection of the low-vibration phase window.

[0064] S302. Read the pre-stored low-vibration phase window based on the stiffness grade and real-time roll diameter.

[0065] The pre-stored low-vibration phase window is not a single fixed value, but is stored in the form of a two-dimensional lookup table. The two index dimensions of this lookup table are: First dimension: Stiffness level parameter (Discrete values, such as 1~5); Second dimension: Real-time volume diameter D (continuous value, which can be divided into several intervals, such as 300–400mm, 400–500mm, 900–1000mm). Each index combination Corresponding to a specific low vibration phase window .

[0066] This lookup table was pre-built through offline calibration experiments. The specific process is as follows: For each typical cable type (corresponding to one...), ... On a laboratory winding platform, winding tests were conducted under multiple typical winding diameters (e.g., empty, half-full, full reel). First, a high-precision TSH-50k tension sensor and a laser vibration meter were used to simultaneously collect cable tension and vibration signals. Second, the tension data within a complete winding cycle (360°) was segmented and statistically analyzed to calculate the tension standard deviation or vibration energy (e.g., RMS value) for each phase interval. Then, the continuous phase interval with the smallest tension fluctuation (i.e., the lowest standard deviation) was selected as the low-vibration phase window for this condition. Finally, the results were entered into a lookup table. For example, some data in the lookup table might be as shown in Table 1 below:

[0067] Table 1:

[0068]

[0069] In an exemplary embodiment, if the current winding phase angle is not within the low vibration phase window range, such as Figure 4 As shown, in step S700, the previous effective tension value is used as the current effective tension value. Specifically, S701, based on the preset tension attenuation model, the current estimated tension value is calculated based on the previous effective tension value and the time interval elapsed from the time the previous effective tension value was acquired to the current time.

[0070] Specifically, the previous effective tension value This refers to the tension value successfully acquired by the tension sensor and verified for validity (e.g., amplitude within a reasonable range, no abrupt changes) when the current winding phase corner enters a low-vibration phase window most recently. This value and its corresponding timestamp are also included. It is stored. The time interval elapsed from the time it was acquired to the current time is denoted as . ,in This is the time of the current control cycle, which can be obtained from the controller's internal timer.

[0071] The tension decay model is an empirical or semi-empirical mathematical function used to describe the physical process of cable tension slowly decaying over time due to internal energy dissipation during periods without effective tension sampling. This model is based on an in-depth analysis of take-up dynamics, and its physical mechanisms mainly include the following three aspects: Aspect 1: Guide roller bearing friction: As the cable passes over the guide roller, the static and dynamic friction of the roller bearings continuously consumes tension energy; Aspect 2: Reel rotation resistance: This includes spindle bearing friction, air resistance, and the slight vibration damping caused by reel imbalance; Aspect 3: Viscoelastic creep of the cable material: For cables with polymer insulation layers (such as PVC, XLPE) or composite structures, stress relaxes over time under constant strain, leading to natural tension decay. Considering the above factors, this embodiment adopts the exponential decay model as the preferred implementation of the tension decay model, and its expression is: ;in: This is the current estimated tension value; Tension attenuation coefficient (unit: s) −1 (Stiffness rating) is a key parameter characterizing the rate of energy dissipation; for flexible PVC cables (stiffness rating) ), For rigid armored cables (stiffness rating) Because of its weak creep effect, If the take-up speed is high (10m / s), frictional heat will cause the material to soften. It can be increased appropriately.

[0072] Optionally, the model parameters The following methods can be used for pre-setting: Offline calibration: Under typical working conditions, the tension sensor output is manually shielded, the natural tension decay curve is recorded, and the result is obtained by least squares fitting. Alternatively, online self-learning can be used: leveraging tension data within the window period and historical estimation errors outside the window period, the Recursive Least Squares (RLS) algorithm is employed to update data in real time. (This is an optional advanced function). For example, in a certain control cycle, the previous effective tension value The time interval Δt = 8ms = 0.008s, and the attenuation coefficient is... The current estimated tension value is: .

[0073] S702. Use the current estimated tension value as the current effective tension value.

[0074] Specifically, when it is determined that the current winding phase angle does not fall within the low-vibration phase window, the controller does not use the original output of the tension sensor (because it may contain significant vibration interference), but instead uses the calculated current estimated tension value. The current effective tension value for the current control cycle ,Right now: .

[0075] In this embodiment, the above steps S701~S702 ensure that even during periods when sensor data is unreliable, a physically reasonable, continuous, smooth, and reliable tension feedback value can still be obtained, thereby avoiding control oscillations or malfunctions caused by sampling noise or vibration interference.

[0076] In one exemplary embodiment, such as Figure 5 As shown, S800 adjusts the speed of the take-up spindle through torque control commands. Specifically, S801 calculates the mechanical phase interval corresponding to the commutation cycle of the spindle drive motor based on the current winding phase angle and the obtained number of pole pairs of the spindle drive motor.

[0077] The spindle drive motor is either a permanent magnet synchronous motor or a brushless DC motor, and its operation relies on electronic commutation. (Number of pole pairs) These are inherent parameters of the motor (e.g.) This represents the number of electrical cycles the rotor completes one revolution. This parameter is pre-stored on the motor nameplate or in the driver parameter library and can be directly read by the controller. (Electrical angle of the motor) With mechanical angle The relationship is: Therefore, the mechanical angle range corresponding to the motor completing one full electrical cycle (360° electrical angle) is: This interval is the mechanical phase interval corresponding to the commutation cycle.

[0078] In this embodiment, the current winding phase angle That is, mechanical angle The controller uses this information to determine the current commutation interval. For example, if the number of pole pairs of the motor... Therefore, each commutation cycle corresponds to a mechanical phase interval of 90° (i.e., 360° / 4). When the current winding phase angle θ = 158.34°, its commutation interval is the second interval: [90°, 180°). This calculation can be efficiently achieved through modulo operations. .

[0079] S802 generates a periodic compensation torque signal synchronized with the mechanical phase interval.

[0080] Among them, the periodic compensation torque signal It is a function with the motor commutation cycle as its fundamental period, used to counteract periodic tension disturbances caused by electromagnetic torque pulsation (ripple torque) or mechanical imbalance in the motor. The waveform of this signal can take any of the following forms: Form 1, sine / cosine waveform: Form 2: Lookup table waveform: Based on the torque pulsation curve measured offline, construct a compensation table that matches the electrical angle; Form 3: Fourier series synthesis: Includes the fundamental wave and the main harmonic components.

[0081] Specifically, the period of this signal must be strictly synchronized with the commutation period of the motor, meaning its phase zero point must be aligned with the motor's electrical angle zero point. For example, when the motor is at a mechanical angle of θ=0°, the compensation signal should also be at the start of its period. The amplitude A and phase offset ϕ of this compensation signal can be determined in the following ways: First method, offline calibration: Under no-load or constant tension conditions, measure the periodic fluctuations of the motor's output torque, and then generate the compensation signal in reverse; Second method, online adaptive: Dynamically adjust A and ϕ using the q-axis current harmonic analysis results (this is an advanced function). For example, for a servo motor with p=4, if its main torque pulsation is measured to be a 6th harmonic of the electrical frequency, then the compensation signal can be set as: .

[0082] S803: The periodic compensation torque signal is superimposed on the torque control command to obtain the compensation torque command.

[0083] Among them, torque control command It is a feedback torque command (unit: N·m) generated based on tension error using algorithms such as PID. The controller will periodically compensate for the torque signal. Adding this algebraically, we obtain the final compensation torque command. This superposition operation is completed in real time within each control cycle, thereby ensuring that feedforward compensation and feedback control can work together.

[0084] S804: Adjust the speed of the take-up spindle by means of a compensation torque command.

[0085] Among them, the compensation torque command The data is sent to the servo driver via a real-time industrial bus. The driver converts this data into a q-axis current command. (according to (where the torque is constant), and the motor outputs precise electromagnetic torque through a current loop, thereby dynamically adjusting the speed of the take-up spindle to achieve high-precision control of cable tension.

[0086] Furthermore, the amplitude of the periodic compensation torque signal does not exceed a preset proportional threshold of the torque control command amplitude, and its phase is aligned with the mechanical phase range to avoid phase conflict with the feedback control. Specifically, this includes: amplitude limitation: assuming a preset proportional threshold (e.g., η=20%), then the following is required: ,when When the tension is close to zero (e.g., the tension has stabilized), a minimum protection value can be set (e.g., ...). To prevent excessive compensation signal from causing oscillations, the phase of the compensation signal must be strictly synchronized with the actual electrical angle of the motor. This can be achieved by calculating the electrical angle in real time using the mechanical angle fed back by the encoder, thus ensuring that the feedforward compensation is applied at the correct time, rather than exacerbating the disturbance in the opposite direction.

[0087] In this embodiment, the aforementioned limiting mechanism effectively prevents phase cancellation or resonance amplification between feedforward compensation and feedback control, thus ensuring the control stability of tension control.

[0088] In one exemplary embodiment, such as Figure 6 As shown, after adjusting the spindle speed through torque control command to control the cable winding tension, the method further includes step S900, which is as follows: S901, when the winding control system is in a stable tension control state, read the q-axis current signal of the spindle drive motor.

[0089] Among them, the tension control stable state refers to the winding entering the normal operation stage and meeting any one or a combination of the following conditions: Condition (1) The absolute value of the deviation between the current effective tension and the target tension is less than the preset tolerance (e.g., ±0.5N); Condition (2) The variance of the tension error is lower than the threshold in multiple consecutive control cycles; Condition (3) The speed fluctuation of the winding spindle is less than ±0.1% of the rated speed. Under this state, the tension closed loop is considered to have converged, and the motor current signal collected at this time can better reflect the steady-state disturbance characteristics, rather than the transient response during the start-up or speed change process.

[0090] Among them, the q-axis current signal It is the torque component current of the permanent magnet synchronous motor under the field-oriented control framework, which is proportional to the output electromagnetic torque of the motor (the relationship is...). ,in (This is a torque constant). This signal is sampled in real time by the servo driver via an internal current sensor and provided to the central controller through a communication interface. Optionally, the controller continuously samples at a fixed sampling rate. Data, forming time series .

[0091] S902. Perform harmonic analysis on the q-axis current signal and calculate the total harmonic distortion content.

[0092] Harmonic analysis is used to identify periodic harmonic components in the q-axis current other than the fundamental wave (corresponding to the average torque). These harmonics typically originate from: motor cogging torque; inverter switching ripple; periodic friction or imbalance in the mechanical drivetrain; and periodic load disturbances caused by cable winding. Total Harmonic Distortion (THD) is a standardized metric measuring the degree of distortion in the current waveform, and its calculation formula is as follows: ,in: This represents the effective value of the fundamental current. This represents the effective value of the kth harmonic current. For the highest harmonic order analyzed (e.g.) ).

[0093] This calculation can be performed in either of the following ways: Method 1, Fast Fourier Transform (FFT): For a given period of time, the calculation can be performed using either of the following methods. Method 1: Perform FFT on the signal to extract the amplitude of each harmonic; Method 2: Digital filter bank: Use bandpass filters to extract each harmonic separately; Method 3: Dedicated harmonic analysis module: Some high-end servo drives have built-in THD calculation functions and can directly output the results. For example, under a certain stable operating condition, the measured... If the effective value of the higher harmonic synthesis is 0.3A, then... .

[0094] S903. If the total harmonic distortion content exceeds the preset electrical interference threshold N times consecutively, and the duration exceeds the preset duration, the tension control indication is triggered to execute the subsequent tension control process.

[0095] Among them, the preset electrical interference threshold This is an empirically set value (e.g., 12%) used to determine whether there is significant periodic electrical or electromechanical interference. This threshold can be configured based on motor type, cable specifications, or historical data. To avoid false triggering due to transient noise, this embodiment introduces dual judgment conditions: Condition 1, continuous... Second time exceeding the limit: The value exceeds [a certain value] in N consecutive analysis periods (e.g., N=3). Condition 2, Duration Exceeds Limit: From the first time the limit is exceeded, the cumulative time exceeding the limit exceeds the preset duration. (For example Only when both conditions are met simultaneously is a persistent periodic disturbance identified, requiring a re-optimization of the compensation strategy. In this case, the controller actively triggers a tension control indication, initiating a new round of tension control procedures. This mechanism effectively prevents frequent readjustments caused by accidental disturbances (such as power grid fluctuations or mechanical shocks), thus improving robustness.

[0096] S904. In the subsequent tension control process, a periodic compensation torque signal synchronized with the mechanical phase interval is generated based on the total harmonic distortion content.

[0097] Where N is an integer greater than or equal to 1. In the new round of control flow, the controller not only uses the basic compensation signal, but also dynamically adjusts the amplitude of the compensation torque signal to correlate it with the detected THD level.

[0098] Specifically, a higher THD level indicates a stronger periodic disturbance, and the amplitude of the compensation signal should be increased accordingly; a system can be established. The mapping relationship with the compensation amplitude A, such as a linear relationship: ,in Based on the compensation amplitude, This is the gain factor (e.g., 0.05 N·m / %). Simultaneously, the phase of the compensation signal remains strictly aligned with the mechanical phase range to ensure that the feedforward compensation acts on the correct disturbance phase. For example, if... Then the compensation amplitude increment is This signal is then superimposed onto the original compensation signal.

[0099] In this embodiment, adaptive feedforward compensation based on electrical state perception is realized, which significantly improves the ability to suppress unknown or time-varying periodic interference.

[0100] In one exemplary embodiment, such as Figure 7 As shown, S500 acquires the real-time tension value output by the tension sensor in response to the enable signal, specifically: S510, acquires the cable winding speed.

[0101] Among them, the take-up linear velocity v refers to the instantaneous linear velocity of the cable on the take-up path (unit: m / s), which is a key process parameter affecting the dynamic response of tension and the stability of sensor sampling.

[0102] This speed can be obtained in either of the following ways: Method 1 (calculated based on spindle speed): Using the acquired spindle rotation angle signal, calculate the spindle angular velocity ω (unit: rad / s) through differentiation or difference, and then calculate it in real time according to the roll diameter D, based on the linear velocity formula: For example, when ω=10.5rad / s and D=0.6m, v=(10.5×0.6) / 2=3.15m / s. Method 2 (direct measurement): Install a non-contact speed measuring device (such as a laser Doppler velocimeter, rotary encoder guide roller) on the take-up path to directly output the linear velocity signal.

[0103] S520. Calculate the gradual change time corresponding to the enable signal based on the take-up line speed.

[0104] The gradual transition time τ refers to the smooth transition time (unit: ms) required for the enable signal to rise from an inactive level (e.g., 0V or logic 0) to an active level (e.g., 5V or logic 1), or fall from an active level to an inactive level. This design aims to prevent step switching of the enable signal from causing high-frequency electromagnetic interference or sudden changes in the sensor signal, thereby affecting the stability of the tension measurement. In this embodiment, the gradual transition time... It is inversely proportional to the linear velocity v of the take-up line, that is... Where k is a proportionality constant (unit: m), its physical meaning is the equivalent slowly varying distance, which can be calibrated according to the response characteristics. For example, if k = 0.02 m, then: when v = 1 m / s, τ = 20 ms; when v = 5 m / s, τ = 4 ms.

[0105] The principle behind this relationship is that at high speeds, the cable spends less time in the low-vibration window, and if the transition time is too long, it will result in insufficient effective sampling time. At low speeds, a smoother transition is allowed to improve signal quality. Therefore, dynamically adjusting τ can achieve the optimal balance between sampling time and signal smoothness at different speeds.

[0106] S530. During the period when the current winding phase corner enters the low vibration phase window, the control enable signal gradually rises from the invalid level to the valid level over a slow change time, and remains at the valid level before exiting the window.

[0107] The controller monitors the current winding phase angle θ and the low-vibration phase window in real time. The relative position of θ. When it is detected that θ is about to enter the window (e.g., Δθ = 2° in advance), the rising edge of the enable signal is gradually changed. This gradual change can be implemented using any of the following waveforms: Waveform 1, Linear ramp: Enable signal Waveform 2, S-shaped curve (such as sigmoid): provides a smoother acceleration transition and reduces high-frequency components. For example, if τ=10ms, the enable signal will linearly rise from 0V to 5V within 10ms and remain constant at 5V while the phase angle is within the window (such as θ∈[110°,170°]), ensuring that the tension sensor continuously outputs valid data throughout the low vibration range.

[0108] S540. When the current winding phase angle exits the low vibration phase window, the control enable signal gradually decreases from the effective level to the ineffective level over a slow change time.

[0109] Specifically, when it is detected that θ is about to exit the window (e.g., Δθ = 2° in advance), a gradual transition process of the falling edge of the enable signal is initiated, lasting for a time τ, smoothly decreasing from the effective level to the ineffective level. This design avoids abrupt truncation of the sensor output, preventing Gibbs phenomenon or ADC sampling glitches during data acquisition.

[0110] S550: Acquire the real-time tension value output when the tension sensor response enable signal is at an effective level.

[0111] The controller reads the tension sensor's output value as the real-time tension value only when the enable signal is within the valid level range (i.e., between the end of the rising edge and the beginning of the falling edge). During this period, the sensor signal is considered to be in a stable, low-interference state, suitable for high-precision tension feedback. For example, if the low-vibration window is 60° and the spindle speed is 60 rpm (i.e., 1 rpm), the window passage time is (60° / 360°) / 1 = 166.7 ms. If the gradual change time is 10 ms, the effective sampling time is 166.7 − 2 × (10 × 360° / 360°) ≈ 146.7 ms, which is sufficient to complete multiple high-precision sampling and filtering.

[0112] In one exemplary embodiment, before determining whether the current winding phase angle falls within the low-vibration phase window, such as Figure 8 As shown, the method also includes S410~S420: S410, determining whether the total number of turns has reached the preset number of turns at the end of the full plate.

[0113] Wherein, the total number of turns N represents the total number of complete turns of the cable on the take-up reel. The preset number of turns at the end of the full reel. This is a process setting value used to indicate the stage where the take-up process is about to end (e.g., the last 50 turns or the last 3 layers). This value can be pre-calculated based on the physical dimensions of the take-up reel, the cable diameter, and the cabling density, and is stored in the controller's parameter library. For example, for a take-up reel that can wind a maximum of 1000 turns, this setting can be... The judgment logic is: if If the condition is met, the system enters the final stage of full-system control. This judgment is executed within each control cycle and serves as the trigger condition for whether to enable the full-system special control strategy.

[0114] S420. If the condition has been met, reduce the window width of the pre-stored low-vibration phase window to obtain a full-disk phase window, and extend the gradual change time of the enable signal, and the extended gradual change time shall not exceed the preset maximum allowable delay time.

[0115] The pre-stored low-vibration phase window is the standard window in S30 (e.g., [110.0°, 170.0°], with a width of 60°). At the end of the full reel, due to the maximum outer diameter of the take-up reel and the maximum number of cable stacking layers, the bending curvature of the cable at the edge of the reel increases sharply, resulting in a narrowing of the vibration-sensitive area. The original window may contain some high-interference phases.

[0116] Therefore, this embodiment reduces the window size to generate a full-disc phase window. Specific implementation methods include: symmetrical narrowing: using the original window center as a reference, the window is reduced by an angle Δθ on both sides. For example, the original window [110°, 170°] (center 140°) becomes [120°, 160°] after being narrowed by 20°; asymmetrical narrowing: based on full-disc vibration test data, only the high-interference side (such as the exit side) is narrowed; proportional narrowing: the window width is multiplied by a narrowing coefficient α (e.g., α = 0.7), the new width = α × original width. This narrowing amount Δθ or coefficient α can be calibrated through offline experiments and pre-stored as equipment parameters. For example, for a certain type of PVC flexible wire, in a full-disc state, the window width is reduced from 60° to 40° to ensure that sampling is only performed in the most stable phase interval.

[0117] The gradual change time τ of the enable signal is dynamically calculated based on the linear velocity (τ=k / v). At the end of the full reel, given that cable tension is more sensitive to disturbances (large reel inertia and slow response), the gradual change time needs to be further extended to achieve smoother sensor enable switching and avoid introducing small step interference.

[0118] Alternatively, the extended processing method may be: Where β>1 is the extension coefficient (e.g., β=1.5). To prevent the effective sampling window from being excessively compressed due to an excessively long gradual change time (especially during high-speed line reception), this embodiment sets an upper limit constraint: ,in, This is the preset maximum allowable delay time (e.g., 20ms), which is set based on the minimum effective sampling time requirement. For example, if the window width is only 40° when the disk is full and the spindle speed is 2 rpm, then the window passage time is: (40 / 360) / 2≈55.6ms. The gradual rise and fall together occupy 40ms, leaving approximately 15ms of effective sampling time to meet control requirements.

[0119] Based on S410 and S420, S500 is used to determine whether the current winding phase angle falls into the low vibration phase window. Specifically, it determines whether the current winding phase angle falls into the full-disc phase window.

[0120] In the final stage of winding, the low-vibration phase window is replaced by the full-wave phase window. The subsequent phase judgment logic remains unchanged, but the comparison object is updated. For example, if the current winding phase angle is 158.34° and the full-wave phase window is [120.0°, 160.0°], the judgment result is yes; if it is 162.0°, the result is no. This mechanism ensures that tension sampling only occurs within the most reliable and stable minimum range during the most critical final stage of winding, greatly improving the quality of the full-wave winding (avoiding defects such as loose end wire and collapsed edges).

[0121] Based on S410 and S420, S600 is used to acquire the real-time tension value output by the tension sensor in response to the enable signal. Specifically, it acquires the real-time tension value output by the tension sensor in response to the enable signal, which includes the extended processing time of the gradual change.

[0122] In the final stage of the full-scale test, both the rise and fall of the enable signal utilize extended, gradual time intervals. The controller only reads the tension sensor output as the real-time tension value during the period when the enable signal is at a valid level (i.e., between the end of the gradual rise and the start of the gradual fall). For example, assuming τ = 10 ms and β = 1.5, then... If the full-disk window transit time is 50ms, then the effective sampling time is 50−2×15=20ms, which is still sufficient to complete multiple filtering samples. This design achieves a balance between signal smoothness and sampling effectiveness, and is specifically optimized for high-precision full-disk control.

[0123] In one exemplary embodiment, such as Figure 9 As shown, after adjusting the spindle speed via torque control command to control cable winding tension, steps S1001~S1005 are executed:

[0124] S1001. When the winding control system is in a stable tension control state, the continuous tension signal within a complete winding turn is collected.

[0125] Among them, the tension control stable state refers to the state of steady operation, which meets the following conditions: Condition ①, the absolute value of the deviation between the current effective tension value and the target tension value is less than the preset tolerance (e.g., ±0.3N); Condition ②, the spindle speed fluctuation is less than ±0.05% of the rated speed; Condition ③, no external disturbance events (such as disc replacement, wire breakage alarm) occur.

[0126] In this state, the controller initiates a full-cycle tension data acquisition task. The acquisition process is as follows: The tension sensor output is continuously read at a high sampling rate (e.g., 1kHz) (the enable signal is active at this time, or the estimated value from S701 is used for correction); the corresponding current winding phase angle θ(t) is recorded synchronously; when the phase angle completes a full cycle (i.e., from any starting angle...), the acquisition process continues. arrive (The acquisition is stopped, forming a tension-phase sequence containing M data points.) For example, when the spindle speed is 1.5 rpm, a single revolution takes about 667 ms. With a sampling frequency of 1 kHz, about 667 tension data points can be obtained, covering the entire mechanical cycle.

[0127] S1002. Perform spectral analysis on the continuous tension signal to identify the phase interval with the smallest standard deviation of the tension signal, which is taken as the phase interval with the lowest vibration energy.

[0128] To quantify vibration energy, this embodiment uses local standard deviation as an evaluation index because it effectively reflects the dispersion of tension fluctuations. Specifically, the 360° phase range is divided into several continuous sliding windows (e.g., window width of 30°, step size of 5°), generating a total of K candidate intervals. For each interval Extract all tension data points. Calculate its standard deviation : ;in The number of data points within the interval. The mean value is used; the interval with the smallest standard deviation is selected as the phase interval with the lowest vibration energy. For example, calculations show that the standard deviation of the interval [125.0°, 155.0°] is 0.12N, which is the smallest among all intervals. .

[0129] S1003. Take the intersection of the phase interval with the lowest vibration energy and the currently used phase window as the updated phase window.

[0130] The currently used phase window is the currently active window, which may be the low vibration phase window of S302 (e.g., [110.0°, 170.0°]) or the full-disc phase window in S402 (e.g., [120.0°, 160.0°]).

[0131] To ensure that the updated window remains within the safety limits of the original design, this embodiment uses an intersection operation: for example: ;like , ,but ;like The intersection is This mechanism ensures the safety and stability of updates by limiting the window drift range and preventing the window from entering a high-vibration area due to noise or accidental disturbances.

[0132] S1004. If the updated phase window is inconsistent with the currently used phase window, a tension control instruction is triggered to execute the subsequent tension control process.

[0133] Inconsistency refers to significant differences between the two windows in terms of boundary position or width, such as a width change exceeding 5° or a center offset exceeding 3°. If consistent, no update is needed. Once inconsistency is determined, the controller actively triggers a tension control indication, initiating a new round of control flow, and... This triggering mechanism serves as the new current window for subsequent phase determination. It implements a closed-loop self-optimization function, dynamically adjusting the sampling window based on actual operating data to adapt to time-varying factors such as cable aging, temperature changes, and bearing wear.

[0134] S1005. In the subsequent tension control process, based on the updated phase window, determine whether the current winding phase angle falls within it.

[0135] In this new round of control, all phase determinations use the updated window. This ensures that tension sampling always occurs within the optimal low-vibration range measured under the current operating conditions, improving control accuracy. If the current state is at the end of the full-disc phase, the width of the update phase window must not exceed the width of the full-disc phase window. When in the end of the full-disc phase (i.e., Even when obtained through online analysis It is relatively wide, and its intersection with the full-pane window It is also naturally limited by the boundaries of the entire window. Furthermore, to strengthen the constraint, if... Then the forced scissors cut to Within the range.

[0136] In this embodiment, it is ensured that the window during the full-disk stage never exceeds the preset safety narrowing range to prevent the quality of the tail line from deteriorating due to online misjudgment.

[0137] It should be understood that although the steps in the flowcharts of the above embodiments are shown sequentially as indicated by arrows, the execution order of these steps is not necessarily so. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the above embodiments may include multiple steps or multiple stages, which are not necessarily completed at the same time, but may be executed at different times, and the execution order of these steps or stages is not necessarily sequential, but may be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0138] Based on the same inventive concept, this application also provides an automated control system for wire and cable production to implement the aforementioned automated control method for wire and cable production. This device is specifically designed to improve operational stability. For example, in valve body processing, the cooperation between the limiting plate and the support block effectively supports the bottom of the valve body, greatly reducing instability factors during processing. The solution provided by this device is similar to the solution described in the above method. Therefore, the specific limitations of one or more embodiments of the automated control system for wire and cable production provided below can be found in the above-described limitations of the automated control method for wire and cable production, and will not be repeated here.

[0139] In one exemplary embodiment, such as Figure 10 As shown, an automated control system for wire and cable production is provided. The system includes an angle acquisition module 11, which is used to acquire the rotation angle signal of the take-up spindle.

[0140] The phase decomposition module 12 is used to decompose the rotation angle signal into the total number of turns wound and the current winding phase angle; wherein, the current winding phase angle represents the angular position of the cable in the current unfinished winding turn.

[0141] The window reading module 13 is used to read the pre-stored low vibration phase window; wherein, the low vibration phase window is a preset angle range, corresponding to the winding phase range where the vibration interference caused by the bending of the cable is minimal.

[0142] Phase determination module 14 is used to determine whether the current winding phase angle falls within the low vibration phase window.

[0143] The tension sampling control module 15 is used to output an enable signal to the tension sensor and acquire the real-time tension value output by the tension sensor in response to the enable signal when the current winding phase angle falls into the low vibration phase window; and to acquire the pre-stored previous effective tension value when the current winding phase angle does not fall into the low vibration phase window.

[0144] The effective tension determination module 16 is used to take the real-time tension value or the previous effective tension value as the current effective tension value.

[0145] The torque generation module 17 is used to compare the current effective tension value with the preset target tension value and generate torque control commands based on the comparison results.

[0146] The speed adjustment module 18 is used to adjust the speed of the take-up spindle through torque control commands in order to control the take-up tension of the cable.

[0147] Each module in the aforementioned automated control system for wire and cable production can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in or independent of the processor in a computer device, or stored in the computer device's memory as software, so that the processor can call and execute the corresponding operations of each module.

[0148] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as the combination of these technical features does not contradict each other, it should be considered within the scope of this application.

[0149] The embodiments described above are merely examples of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of patent protection of this application. The scope of patent application protection refers to the boundary of protection for the technology or invention covered by the patent application; it defines the scope of the exclusive rights legally held by the patentee. It should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of this application, and these all fall within the scope of protection of this application. Given the central role of the claims in a patent application and their importance in determining the scope of patent protection, the scope of protection of this application should be strictly defined according to the appended claims.

Claims

1. An automated control method for wire and cable production, characterized in that, The method includes: responding to a tension control instruction and executing a tension control process; wherein the tension control process includes the following steps: acquiring a rotation angle signal of the take-up spindle; calculating the take-up speed based on the rotation angle signal and generating an initial tension control signal in conjunction with a preset tension value; decomposing the rotation angle signal into the total number of turns wound and the current winding phase angle; wherein the current winding phase angle represents the angular position of the cable in the current unfinished winding turn; reading a pre-stored low-vibration phase window; wherein the window is a preset angle range corresponding to the turn where the vibration interference caused by the cable bending is minimal. The system calculates the winding phase range; determines whether the current winding phase angle falls within the low-vibration phase window; if so, it outputs an enable signal to the tension sensor and acquires the real-time tension value output by the tension sensor in response to the enable signal; if not, it acquires the previously stored effective tension value; it uses the real-time tension value or the previously effective tension value as the current effective tension value; it compares the current effective tension value with the preset target tension value and generates a torque control command based on the comparison result, adjusting the rotation speed of the take-up spindle through the torque control command to control the take-up tension of the cable.

2. The method as described in claim 1, characterized in that, Determining whether the current winding phase angle falls within the low vibration phase window involves: calculating the real-time winding diameter of the take-up reel based on the total number of windings, the obtained cable diameter parameters, and the initial reel diameter parameters; and calculating the number of layers formed on the take-up reel based on the real-time winding diameter and the preset cable pitch. Calculate the change in helix angle of the cable spiral path based on the real-time roll diameter and the number of layers; Based on the change in the helix angle, the current winding phase angle is corrected to obtain the corrected current winding phase angle; it is determined whether the corrected current winding phase angle falls within the low vibration phase window; wherein, the wire laying pitch is determined based on the synchronous operation relationship between the wire laying mechanism and the take-up spindle.

3. The method as described in claim 2, characterized in that, Reading the pre-stored low vibration phase window specifically involves: obtaining the stiffness level corresponding to the cable type; and reading the pre-stored low vibration phase window based on the stiffness level and the real-time roll diameter.

4. The method as described in claim 1, characterized in that, If the current winding phase angle does not fall within the low vibration phase window, the previous effective tension value is used as the current effective tension value. Specifically, based on a preset tension decay model, the current estimated tension value is calculated based on the previous effective tension value and the time interval elapsed from the acquisition time of the previous effective tension value to the current time. The tension decay model characterizes the physical characteristic that the cable tension slowly decreases over time due to the combined effects of friction of the guide roller bearing, rotational resistance of the take-up reel, and viscoelastic creep of the cable material during the period when the tension sensor output is prohibited because the current winding phase angle does not fall within the low vibration phase window. The current estimated tension value is used as the current effective tension value.

5. The method as described in claim 1, characterized in that, The rotational speed of the take-up spindle is adjusted by the torque control command, specifically by calculating the mechanical phase interval corresponding to the commutation cycle of the spindle drive motor based on the current winding phase angle and the obtained number of pole pairs of the spindle drive motor. A periodic compensation torque signal synchronized with the mechanical phase interval is generated; the periodic compensation torque signal is superimposed on the torque control command to obtain a compensation torque command; the rotational speed of the take-up spindle is adjusted by the compensation torque command; wherein the amplitude of the periodic compensation torque signal does not exceed a preset proportional threshold of the amplitude of the torque control command, and its phase is aligned with the mechanical phase interval to avoid phase conflict with the feedback control.

6. The method as described in claim 5, characterized in that, After adjusting the rotational speed of the take-up spindle via the torque control command to control the take-up tension of the cable, the method further includes: when the take-up control system is in a stable tension control state, reading the q-axis current signal of the spindle drive motor; performing harmonic analysis on the q-axis current signal to calculate the total harmonic distortion (THD) content; if the THD content exceeds a preset electrical interference threshold N times consecutively and the duration exceeds a preset duration, triggering the tension control instruction to execute the subsequent tension control process; in the subsequent tension control process, generating a periodic compensation torque signal synchronized with the mechanical phase interval based on the THD content; where N is an integer greater than or equal to 1.

7. The method as described in claim 1, characterized in that, To obtain the real-time tension value output by the tension sensor in response to the enable signal, specifically: the cable take-up speed is obtained; based on the take-up speed, the gradual change time corresponding to the enable signal is calculated, where the gradual change time is inversely proportional to the take-up speed; during the period when the current winding phase angle enters the low-vibration phase window, the enable signal is controlled to gradually rise from an invalid level to an effective level over the gradual change time, and remains at an effective level until exiting the window; when the current winding phase angle exits the low-vibration phase window, the enable signal is controlled to gradually decrease from an effective level to an invalid level over the gradual change time; the real-time tension value output by the tension sensor in response to the enable signal being at the effective level is obtained.

8. The method as described in claim 7, characterized in that, Before determining whether the current winding phase angle falls within the low-vibration phase window, the method further includes: determining whether the total number of winding turns has reached a preset number of turns at the end of the full disk; if it has, then reducing the window width of the pre-stored low-vibration phase window to obtain a full disk phase window, and extending the gradual change time of the enable signal, wherein the extended gradual change time is not greater than a preset maximum allowable delay time; correspondingly, determining whether the current winding phase angle falls within the low-vibration phase window specifically involves: determining whether the current winding phase angle falls within the full disk phase window; obtaining the real-time tension value output by the tension sensor in response to the enable signal specifically involves: obtaining the real-time tension value output by the tension sensor in response to the enable signal including the extended gradual change time.

9. The method as described in claim 8, characterized in that, After adjusting the rotational speed of the take-up spindle via the torque control command to control the take-up tension of the cable, the method further includes: when the take-up control system is in a stable tension control state, acquiring a continuous tension signal within a complete winding turn; performing spectral analysis on the continuous tension signal to identify the phase interval with the smallest standard deviation of the tension signal as the phase interval with the lowest vibration energy; taking the intersection of the phase interval with the lowest vibration energy and the currently used phase window as the updated phase window; wherein, the currently used phase window is the low vibration phase window or the full-coil phase window; if the updated phase window is inconsistent with the currently used phase window, triggering the tension control instruction to execute the subsequent tension control process; in the subsequent tension control process, determining whether the current winding phase angle falls within the updated phase window; wherein, if the current state is at the end of the full-coil state, the width of the updated phase window does not exceed the width of the full-coil phase window.

10. A winding tension anti-interference control system for wire and cable production, characterized in that, The system includes: an angle acquisition module for acquiring the rotation angle signal of the take-up spindle; a phase decomposition module for decomposing the rotation angle signal into the total number of turns wound and the current winding phase angle; wherein the current winding phase angle represents the angular position of the cable in the current unfinished winding turn; a window reading module for reading a pre-stored low-vibration phase window; wherein the low-vibration phase window is a preset angle range corresponding to the winding phase range where the vibration interference caused by the cable bending is minimal; a phase judgment module for judging whether the current winding phase angle falls within the low-vibration phase window; and a tension sampling control module for judging whether the current winding phase angle falls within the low-vibration phase window. When the current winding phase angle falls within the low-vibration phase window, an enable signal is output to the tension sensor, and the real-time tension value output by the tension sensor in response to the enable signal is obtained; and when the current winding phase angle does not fall within the low-vibration phase window, the previously stored effective tension value is obtained; the effective tension determination module is used to use the real-time tension value or the previously effective tension value as the current effective tension value; the torque generation module is used to compare the current effective tension value with a preset target tension value, and generate a torque control command based on the comparison result; the speed adjustment module is used to adjust the speed of the take-up spindle through the torque control command to control the take-up tension of the cable.

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