High-precision controllable stroke tape wrapping machine

Abstract

This invention relates to the field of wire-making equipment technology, and in particular provides a high-precision, stroke-controllable tape winding machine, including a base with a first position and a second position. The first position has a wire hole, and a first drive mechanism is provided inside the wire hole. A winding frame is provided on the first drive mechanism, and a wire clamp is fixed on the winding frame. The clamping jaws coincide with the axis of the wire hole. A tape station is provided on the winding frame at an oblique position corresponding to the clamping jaws. The second position is located on the wire outlet side of the wire clamp. The second position has two upper and lower conveyor roller assemblies, and the winding frame drives the tape station and the wire clamp to rotate between the two conveyor roller assemblies. The second drive mechanism drives the two conveyor roller assemblies to rotate relative to the wire outlet direction of the wire clamp. The multi-strand wire being conveyed is conveyed and positioned. At the same time, the rotational force provided by the first drive mechanism and the linear transmission force provided by the second drive mechanism are also used to wind the tape onto the double-strand wire in a multi-turn winding manner along the outlet direction of the multi-strand wire, so that the double-strand wire is stressed and twisted at multiple positions, improving the quality of wire twisting.

Description

Technical Field

[0001] This invention relates to the field of wire-making equipment technology, and in particular to a high-precision, stroke-controllable tape winding machine. Background Technology

[0002] In industrial sectors such as wire and cable manufacturing and electronic wire harness assembly, combining multiple strands of wire (such as enameled wire and insulated wire) into a single strand via a paralleling process is a common processing requirement. To ensure the stability of the combined wire harness structure, the reliability of its electrical performance, and to meet subsequent processing requirements, insulating tape is typically wrapped around the starting ends, at specific intervals, or on the entire outer surface of the multiple strands for fixation and insulation protection. In traditional processes, this tape wrapping operation generally relies on manual operation by workers or the assistance of simple semi-automatic wrapping equipment. The core function of this equipment is to realize the basic actions of wire rotation and tape wrapping to meet basic stranding and fixing requirements. With the continuous improvement of downstream applications' requirements for wire harness quality and consistency, especially in fields such as precision electronics and new energy vehicle wire harnesses, higher standards have been set for the precision, position control, and efficiency of tape wrapping.

[0003] However, existing tape winding equipment or manual operation methods have significant limitations and cannot meet the requirements of high-precision and intelligent production. Specifically: 1. Existing equipment usually lacks a precise closed-loop control mechanism for the number of winding turns. 2. Low automation and efficiency: When multiple strands are connected, manual winding of the tape onto the multi-strand lines is required, which is inefficient and makes it difficult to control the number of winding turns, resulting in poor flexibility and practicality. 3. Automated equipment occupies a large space, and the multi-strand line directional output structure either lacks directional output or rolling conveyor, and the two auxiliary functions cannot be combined. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a high-precision, stroke-controllable tape winding machine, comprising a base with a first position and a second position. The first position has a wire hole, within which a first drive mechanism is installed. The first drive mechanism has a winding frame, and a wire clamp is fixed on the winding frame. The clamping jaws coincide with the axis of the wire hole. The winding frame has a tape station corresponding to the oblique position of the clamping jaws. The second position is located on the wire exit side of the wire clamp. The second position has two conveyor roller assemblies, one upper and one lower. The second position also has a second drive mechanism. The first drive mechanism drives the winding frame, which in turn drives the tape station and the wire clamp to rotate between the two conveyor roller assemblies. The second drive mechanism drives the two conveyor roller assemblies to rotate relative to the wire exit direction of the wire clamp. The second drive mechanism can also drive the two conveyor roller assemblies to move towards or in opposite directions in the height direction.

[0005] As a further preferred embodiment, a control system is also included, which includes a trial winding module, an image analysis module, and a winding execution module;

[0006] The trial winding module is equipped with a winding simulation command, which is used for the first and second positions to work together so that the cable to be wound is wound to the first state and then restored to the initial state.

[0007] The image analysis module is configured with an image analysis strategy, which is used to analyze the image information of the cable to be wound and generate a winding deviation vector.

[0008] The winding execution module is configured with an execution instruction information library, which stores a number of winding execution instructions. Each winding execution instruction is indexed by a vector matching condition. The winding execution module matches the corresponding winding execution instruction according to the winding deviation vector to generate a winding execution instruction set to control the actions of the first and second camera positions. The winding execution instruction set includes the winding execution instruction corresponding to each attitude angle.

[0009] As a further preferred embodiment, the image analysis strategy includes the following steps:

[0010] Step S1: Obtain the first acquired image in the initial state to obtain the second acquired image in the first state;

[0011] Step S2: Generate a reference parameter set based on the first acquired image using a preset reference recognition algorithm, and generate a corresponding reference comparison function based on the reference parameter set. The reference parameter set includes the number of cable strands, cable diameter, and cable attitude distance value.

[0012] Step S3: Generate a feature parameter set based on the second acquired image using a preset feature extraction algorithm, and input the feature parameter set into the benchmark comparison function to generate the winding deviation vector. The feature parameter set includes the overlapping area of ​​the tape, the winding uniformity value, the winding wrinkle feature value, and the winding tightness value.

[0013] As a further preferred embodiment, the first machine position is provided with an assembly cavity, which communicates with the wire hole. The first drive mechanism includes a plurality of positioning wheels installed around the wire hole in the assembly cavity and a power output wheel assembled between the plurality of positioning wheels. A first motor is also installed in the assembly cavity. A conveyor belt is installed on the power output shaft of the first motor via pulleys. The other end of the conveyor belt is driven and connected to the power output wheel after being oriented and transmitted through all the positioning wheels. The end of the winding frame away from the wire clamp is fixed to the power output wheel.

[0014] As a further preferred embodiment, one end of the winding frame fixed to the power output wheel is perpendicular to the power output wheel. A bent portion inclined towards the axis of the wire hole is provided outward from the fixed end of the winding frame. An assembly portion coinciding with the axis of the wire hole extends further outward from the bent portion of the winding frame. The wire clamp is fixed on the assembly portion, so that the clamp always rotates about the axis of the wire hole. The tape station is set on the bent portion, so that the tape station is offset from the axis of the wire hole.

[0015] As a further preferred embodiment, the upper and lower opposing surfaces of the clamp are provided with relatively protruding arc-shaped extrusion parts, and a gap is left between the two arc-shaped extrusion parts, the gap corresponding to the discharge direction of the tape station.

[0016] As a further preferred embodiment, the second machine position is provided with an ear-type assembly facing the wire outlet side of the wire clamp. The second drive mechanism includes two upper and lower toothed gears that are rotatably connected in the ear-type assembly, an electric cylinder fixed to the top of the second machine position, and a rack mounted on the electric cylinder's actuating rod. The rack enters the second machine position and meshes with one of the toothed gears. The toothed portions of the two toothed gears mesh together. A rotating seat is installed on the non-meshing portion of each of the two toothed gears. A vertically parallel pressure rod is rotatably mounted in each of the two rotating seats. The conveying roller assembly includes a rolling wheel mounted on one end of each of the two pressure rods. A rolling gap is formed between the two rolling wheels, and the rolling gap corresponds to the wire outlet side of the clamp.

[0017] As a further preferred embodiment, each of the two pressure rods is equipped with a driven gear that can mesh with each other at the other end away from the rolling wheel. A second motor is fixed on the second machine position. Two intermediate gears are installed on the outer side of the ear-type assembly. The upper intermediate gear meshes with the upper driven gear, and the lower intermediate gear meshes with the lower driven gear. A driving gear is installed on the power output shaft of the second motor, and the driving gear meshes with the upper intermediate gear.

[0018] As a further preferred embodiment, the first machine position is provided with an L-shaped wire material area, and the wire hole communicates with the wire material area.

[0019] The advantages of this invention compared to the prior art are:

[0020] 1. The tape winding machine is equipped with a first drive mechanism and a second drive mechanism. A winding frame is set on the output side, and a tape station is located on the inclined direction of the winding frame. The first drive mechanism provides rotational power to the wire clamp, and the second drive mechanism provides rotational power to the two conveyor roller assemblies to transmit the multi-strand wire outward. The second drive mechanism also provides opposing or reverse motion forces to the two conveyor roller assemblies in the height direction to position the multi-strand wire being conveyed. At the same time, the rotational force provided by the first drive mechanism and the linear transmission force provided by the second drive mechanism are also used to wind the tape onto the double-strand wire in a multi-turn winding manner along the output direction of the multi-strand wire, so that the double-strand wire is stressed and twisted at multiple points, improving the quality of wire twisting. When the multi-strand wire is output in a directional manner, the second drive mechanism on one station, in conjunction with the upper and lower sets of conveyor roller assemblies, can unify the output guidance and positioning of the multi-strand wire, occupying little space.

[0021] 2. The first position of the tape winding machine is equipped with an intelligent control system to control the number of rotations of the first drive mechanism. The first position is also equipped with a display panel and operation buttons. The user can input commands through the buttons to control the number of rotations of the motor in the first drive mechanism, thereby controlling the number of rotations of the winding frame. Ultimately, the number of rotations of the multi-strand wire driven by the wire clamp is effectively controlled and set, thereby controlling the winding stroke of the tape onto the multi-strand wire, realizing intelligent and effective control, and improving work efficiency. Attached Figure Description

[0022] Figure 1 A top view of a high-precision, stroke-controllable tape winding machine provided for an embodiment of the present invention;

[0023] Figure 2 A three-dimensional schematic diagram of a high-precision, stroke-controllable tape winding machine provided for an embodiment of the present invention. The first machine position is opened in the figure to facilitate viewing the internal first drive mechanism.

[0024] Figure 3 The high-precision, stroke-controllable tape winding machine provided for embodiments of the present invention consists of... Figure 2 This is a schematic diagram from another perspective.

[0025] Figure 4 The high-precision, stroke-controllable tape winding machine provided for embodiments of the present invention consists of... Figure 3 The diagram illustrates another perspective, showing an electric cylinder;

[0026] Figure 5 The high-precision, stroke-controllable tape winding machine provided for embodiments of the present invention consists of... Figure 4 Enlarged schematic diagram of part A;

[0027] Figure 6 The high-precision, stroke-controllable tape winding machine provided for embodiments of the present invention consists of... Figure 3The diagram shows another perspective, in which the second motor has been removed to facilitate viewing the second drive mechanism;

[0028] Figure 7 A schematic diagram illustrating the working principle of a high-precision, controllable-stroke tape winding machine provided for an embodiment of the present invention.

[0029] In the diagram: 1. Machine base; 2. First machine position; 21. Wire hole; 22. First drive mechanism; 221. Positioning wheel; 222. Power output wheel; 23. Winding frame; 231. Bending section; 232. Assembly section; 24. Wire clamp; 241. Clamping jaw; 2411. Arc-shaped extrusion section; 25. Belt station; 26. Assembly cavity; 27. First motor; 28. Conveyor belt; 29. ​​Wire material area; 3. Second machine position; 31. Conveyor roller assembly; 311. Rolling wheel; 32. Second drive mechanism; 321. Gear with missing tooth; 322. Electric cylinder; 323. Rack; 324. Pressure rod; 326. Rolling gap; 327. Driven gear; 328. Second motor; 3281. Drive gear; 329. Intermediate gear. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] In one implementation, such as Figures 1-7 As shown:

[0032] This embodiment provides a high-precision, stroke-controllable tape winding machine, including a base 1. The base 1 has a first machine position 2 and a second machine position 3. The first machine position 2 has a wire hole 21, within which a first drive mechanism 22 is installed. The first drive mechanism 22 has a winding frame 23, and a wire clamp 24 is fixed on the winding frame 23. The clamping opening 241 of the wire clamp 24 coincides with the axis of the wire hole 21. The winding frame 23 has a tape station 25 corresponding to the oblique position of the clamping opening 241. The second machine position 3... On the wire exit side of the wire clamp 24, the second machine position 3 is provided with two upper and lower conveyor roller assemblies 31. The second machine position 3 is provided with a second drive mechanism 32. The first drive mechanism 22 drives the winding frame 23, and the winding frame 23 drives the tape station 25 and the wire clamp 24 to rotate between the two conveyor roller assemblies 31. The second drive mechanism 32 drives the two conveyor roller assemblies 31 to rotate relative to the wire exit direction of the wire clamp 24. The second drive mechanism 32 can also drive the two conveyor roller assemblies 31 to move towards or in opposite directions in the height direction.

[0033] In use, the tape release end on the tape station 25 is pulled into the clamp 241 from the side of the axis of the clamp 241. Then, the lead end of the multi-strand wire is inserted into the clamp 241 of the wire clamp 24 along the wire hole 21. The release end of the tape is manually pre-wound around the multi-strand wire. The foot switch starts the first drive mechanism 22 to drive the winding frame 23 to rotate. The winding frame 23 drives the wire clamp 24 to rotate. The wire clamp 24 drives the clamp 241 to rotate. The clamp 241 drives the multi-strand wire to rotate. Before the clamp 241 rotates, the foot switch simultaneously starts the second drive mechanism 32 to drive the two conveyor roller assemblies 31 to move towards each other to clamp the lead end of the multi-strand wire. While the multi-strand wire rotates through the clamp 241, it can also be conveyed outward through the two conveyor roller assemblies 31. As the multi-strand wire rotates, multiple rolls of tape will be wrapped around its surface. As the multi-strand wire is conveyed outward through the two conveyor roller assemblies 31, the winding pattern of the tape is distributed along the length direction of the multi-strand wire, completing the winding. After the two conveyor roller assemblies 31 are reversed under the drive of the second drive mechanism 32, the multi-stranded wires are dismantled and the next multi-stranded wire merging operation is repeated.

[0034] In addition, the system is equipped with a control system for controlling the first drive mechanism 22 and the second drive mechanism 32. The control system includes an encoder, frequency converter, etc., installed in the first position 2, for controlling the number of rotations of the motor in the first drive mechanism 22, for example, the motor is a stepper motor.

[0035] The control system includes a trial winding module, an image analysis module, and a winding execution module. Its core function is to acquire initial winding state data of the cable and tape through trial winding, quantify the winding deviation through image analysis, generate precise winding execution commands based on the deviation, and ultimately control the coordinated action of the first and second machine positions to ensure the accuracy and stability of tape winding when multiple strands of wire are combined. This control system comprises three core functional modules: a trial winding module, an image analysis module, and a winding execution module. These modules interact in real-time via a data bus, using the industrially common Modbus-RTU protocol, eliminating the need for additional dedicated communication interfaces.

[0036] The trial winding module is equipped with winding simulation commands. These commands are used by the first and second machine positions to wind the cable to be wound to a first state and then restore it to its initial state. It should be noted that the trial winding module winds different types of cables at a preset rotation speed and a preset conveyor speed. After winding, it reverses the process to separate the tape and cable. This is done to obtain cable information through subsequent image analysis, thereby formulating left and right winding strategies. Data such as winding speed and tension at different angles can be generated through analysis without relying on manual experience, ensuring both efficiency and quality when stranding different cables. Preferably, to avoid the adhesive effect of the tape affecting the trial winding, a section of tape without adhesive is set at intervals. After the trial winding is completed, this section of tape is discarded by cutting it off. This reduces the impact of the trial winding on the actual winding work. The core function of the trial winding module is to obtain basic winding characteristic data of the cable by simulating the winding process before formal winding, providing samples for subsequent image analysis and command generation, while avoiding cable damage or winding quality problems caused by improper parameters in the early stages of formal winding. The "winding simulation command" refers to a set of control signals generated by the central processing unit of the control system. These signals include parameters such as the initial speed of the first motor, the initial conveying speed of the second motor, the initial tension of the tape station, and the number of winding turns. Those skilled in the art can directly modify these initial parameters through the parameter configuration interface of the control system. "First state" specifically refers to the state after the trial winding module has completed the set number of winding turns according to the preset parameters.

[0037] The specific workflow of the trial winding module is as follows: First, the operator inserts the lead end of the cable to be wound through the wire hole into the clamp of the wire clamp, pulls the release end of the tape at the tape station to the clamp and pre-fixes it on the multi-strand wire, and then triggers the trial winding module through the start button of the control system; Second, the trial winding module sends a rotation command to the first drive mechanism, controlling the first motor to rotate at an initial speed, which drives the power output wheel and winding frame to rotate through the conveyor belt, thereby driving the wire clamp and tape station to rotate synchronously. At the same time, it sends a conveying command to the second drive mechanism, controlling the second motor to rotate at an initial conveying speed, driving the conveyor roller assembly to convey the multi-strand wire outward, and the tape station releases the tape synchronously, starting the trial winding; Third, when the winding frame rotates to the preset number of turns, the trial winding module sends a pause command to the first and second drive mechanisms. At this time, the cable is in the first state; Finally, the trial winding module starts the recovery process, first controlling the second motor to rotate in the reverse direction, driving the conveyor roller assembly to move in the reverse direction, pulling the multi-strand wire back to the initial position (the pull-back distance is equal to the conveying length during the trial winding process, and the conveying length is calculated using the formula...). ,in The initial conveying speed, To test the winding time, , For the preset number of laps, (The first motor speed is controlled to rotate in the opposite direction, which drives the winding frame to rotate in the opposite direction a preset number of times, unwinding the tape wrapped around the multi-strand wire, and restoring it to its initial state.)

[0038] To avoid the adhesiveness of the tape affecting the recovery effect and subsequent formal winding, the tape at the tape station adopts a structure with intermittently spaced adhesive-free sections. An adhesive-free section refers to a segment of the tape surface without an adhesive coating, with a length set at 10mm. The length of the adhesive section between adjacent adhesive-free sections is set at 50mm. Those skilled in the art can achieve this structure by adjusting the tape manufacturing process or selecting custom tape. During the trial winding process, the tape station prioritizes releasing the adhesive-free sections for winding. After recovery, the control system activates the cutting component installed between the tape station and the wire clamp to cut off the adhesive-free sections of the trial winding tape at the junction of the adhesive-free and adhesive sections, ensuring that adhesive-containing tape is used for subsequent formal winding.

[0039] The image analysis module is configured with an image analysis strategy, which is used to analyze the image information of the cable to be wound and generate a winding deviation vector. The image analysis module is used to collect image information during the trial winding process, extract the feature parameters of the cable and tape through an algorithm, and generate a winding deviation vector after comparing it with the reference parameters, so as to provide a decision basis for the winding execution module. The image analysis strategy refers to the standardized process of image acquisition, parameter extraction, and deviation calculation implemented by the image analysis module, which includes four core steps: image acquisition, baseline parameter generation, feature parameter generation, and deviation vector calculation. The winding deviation vector is a three-dimensional mathematical vector used to quantify the deviation between the trial winding state and the ideal state. Its three components describe the degree of deviation from the three dimensions of winding efficiency, tension, and stability, respectively, providing data support for subsequent parameter adjustments. The baseline parameter set is a set of parameters reflecting the initial state of the cable to be wound, including the number of cable strands, cable diameter, and cable attitude distance value. The feature parameter set is a set of parameters reflecting the tape winding effect in the first state, including the tape overlap area, winding uniformity value, winding wrinkle characteristic value, and winding tightness value. The attitude distance value is the arithmetic mean of the vertical distance between all cable axes and the wire hole axis in the initial state, used to characterize the degree of spatial attitude deviation of the cable before entering the winding mechanism. The smaller the attitude distance value, the more stable the initial attitude of the cable. The image analysis module requires an industrial image acquisition device, which includes an industrial camera, lens, light source, and image acquisition card. The industrial camera is a CMOS industrial camera with a resolution of 1024×768 and a frame rate of 30fps. The lens is a fixed-focus lens with a focal length of 16mm. The light source is a ring LED light source, and the image acquisition card is a PCI-E interface image acquisition card. The acquisition device is installed at the exit of the first camera's cable hole, with the lens axis perpendicular to the cable hole axis. The distance between the lens center and the cable surface is 100mm. The light source is positioned around the lens, and the illumination intensity is adjusted to 500 lux to ensure clear contrast between the cable and the background in the acquired image, without reflections or shadows. The illumination intensity is fine-tuned using a light source controller to obtain a clear image. The image analysis strategy includes the following steps:

[0040] Step S1: Acquire the first image in the initial state and then acquire the second image in the first state. The core of step S1 is to acquire clear images in both the initial and first states, providing a foundation for subsequent parameter extraction. The specific operation is as follows: When the cable is in the initial state, the control system sends a first acquisition command to the image acquisition device. The industrial camera captures three consecutive images, removes blurry or noisy images, and selects the clearest one as the first acquired image. When the trial winding is completed and the cable enters the first state, the control system sends a second acquisition command to the image acquisition device. The industrial camera captures three consecutive images with the same shooting parameters, and again selects the clearest one as the second acquired image. During the shooting process, it is necessary to ensure that the camera position, lighting conditions, and cable position are completely consistent with the first acquired image to avoid image deviations caused by environmental factors.

[0041] Step S2: Generate a reference parameter set based on the first acquired image using a preset reference recognition algorithm, and generate a corresponding reference comparison function based on the reference parameter set. The reference parameter set includes the number of cable strands, cable diameter, and cable posture distance. By analyzing the initial image, the reference information of the cable to be wound, including the number of strands, cable diameter, and cable posture distance, can be obtained. Corresponding comparison parameters are constructed using different reference information because if the initial state of the cable is different, the actual winding command should also be different. Therefore, the reference information of the cable can be obtained by analyzing the first acquired image. First, the initial area of ​​the cable is delineated, and then the edge of the cable is identified according to the edge recognition algorithm. The area with the largest feature difference value is found as the recognition reference. The number of strands, diameter, and distance value are calculated according to the distance, and the basic parameters of the cable can be obtained. It can be optimized that the distance value calculation can take the average of the distances of different cables in multiple areas, and obtain the difference between two average distance values. For example, obtain the difference between the distance values ​​of the first acquired image before and after winding. In this way, the deformation variable can be obtained through the distance difference. This deformation variable can be used as a parameter in the reference parameter set to generate the reference comparison function. The core of step S2 is to extract the initial reference parameters of the cable based on the first acquired image and construct a reference comparison function for subsequent comparisons. First, a reference parameter set is generated using a preprocessing-edge detection-feature extraction process: First, the first acquired image is preprocessed by converting the RGB image to grayscale, then using Gaussian filtering to remove noise. The filter kernel size is set to 5×5, and the standard deviation is... The filtering formula is ,in The coordinates of the filter kernel center are, For the original grayscale image in Pixel value at that location, The first step is to extract the filtered pixel values. The second step uses the Canny edge detection algorithm to extract the cable edges, with a low threshold of 50 and a high threshold of 150. The edge detection process involves calculating the image gradient, performing non-maximum suppression, and finally connecting edges with double thresholds to obtain a binary edge image. The third step uses the Hough transform to detect straight line segments in the edge image, with the Hough transform parameters set to... Precision 1 pixel With an accuracy of 1 degree, each detected straight segment corresponds to the axis of one cable, and the number of straight segments is the number of cable strands. The fourth step is to measure the diameter of each cable. In the binary edge image, along a direction perpendicular to the cable axis, measure the maximum distance between any two points on the edge of each cable, and record this distance as the diameter of the cable. Calculate all The arithmetic mean of the values ​​is used to obtain the cable diameter. Fifth, calculate the attitude distance value, pre-mark the wire hole axis in the image, and measure the perpendicular distance between the axis of each cable and the axis of the wire hole. Calculate all The arithmetic mean of the values ​​is used to obtain the attitude distance value. The above steps generate a baseline parameter set. .

[0042] Next, a benchmark comparison function is constructed. This function comprehensively compares the characteristic parameters with the ideal parameters and outputs a comprehensive value reflecting the quality of the winding state. The expression for the benchmark comparison function is: ,in: The baseline comparison function value ranges from 0 to 1. The closer it is to 1, the closer the winding state is to the ideal state;

[0043] , , , These are weighting coefficients, and their values ​​range from [value range missing]. And satisfy The calibration results in this embodiment are obtained through standard cable testing. Multiple experiments can be conducted using standard cables with known parameters, and the weighting coefficients can be adjusted to make F as close to 1 as possible under the ideal winding state.

[0044] The theoretical overlapping area, i.e., the overlapping area of ​​the tape under ideal conditions, is calculated using the following formula: , This refers to the length of the cable being transported during the trial winding process. , t is the initial conveying speed of the second drive mechanism; U is the trial winding time; W is the winding uniformity value; M is the winding wrinkle characteristic value; and M is the winding tightness value.

[0045] Step S3: Generate a feature parameter set based on the second acquired image using a preset feature extraction algorithm. Substitute the feature parameter set into the benchmark comparison function to generate the winding deviation vector. The feature parameter set includes the overlapping area of ​​the tape, the winding uniformity value, the winding wrinkle feature value, and the winding tightness value. The core of Step S3 is to extract the feature parameters of the tape winding based on the second acquired image and substitute them into the benchmark comparison function to calculate the winding deviation vector. First, the feature parameter set is generated. The second acquired image is processed using the same image preprocessing procedure as in Step S2 (grayscale conversion, Gaussian filtering, Canny edge detection), and then each feature parameter is extracted. The preferred method for determining the overlap area of ​​the tape is to acquire two adjacent second-time images with an interval equal to the time it takes to wrap one turn. The overlap area is obtained by subtracting twice the area of ​​the previous image from the area of ​​the image at the later time. The wrapping uniformity reflects the boundary smoothness of the wire bundle and is calculated by fitting the boundary of the actual wrapped cable image using a smoothness function. The wrapping wrinkle feature value is identified for each wrinkle feature and obtained by multiplying the weight of this type of wrinkle feature by the corresponding wrinkle area and then weighting all wrinkle features. The wrapping tightness is calculated by calculating the diameter of the stranded cable after wrapping. The wrapping deviation vector includes an efficiency deviation component, a tension deviation component, and a stability deviation component. The efficiency deviation component is related to the tape overlap area, boundary smoothness, and deformation variable. The tension deviation component is related to the tape overlap area, number of strands, diameter, distance value, and wrapping wrinkle feature value. The stability deviation component is related to the wrapping wrinkle feature value, wrapping uniformity, wrapping tightness, distance value, number of strands, and diameter.

[0046] The uniformity of cable wrapping refers to the smoothness of the cable's outline after the tape is wrapped, reflecting the uniformity of the wrapping. The calculation method is as follows: In the pre-processed second acquired image, n sampling points are selected along the cable's length, and the coordinates of each sampling point are recorded. The least squares method was used to fit the cable profile curve. Considering that the cable profile is approximately a smooth curve after winding, a quadratic polynomial was selected as the fitting curve, and its expression is as follows: ,in The fitting coefficients are obtained by solving the least squares method, which yields the sum of squared errors. The minimum value can be obtained through matrix operations. ,in , ; Calculate the deviation between each sampling point and the fitted curve. Summing yields Determine the maximum value of the fitted curve within the sampling interval. value ; Calculate the winding uniformity value The value of U ranges from 0 to 1, and the closer it is to 1, the more uniform the winding.

[0047] The wrapping wrinkle feature value refers to the degree of wrinkles generated during the tape wrapping process, reflecting whether the tape tension is appropriate. The calculation method is as follows: In the pre-processed second acquired image, texture features are extracted using a gray-level co-occurrence matrix (GLCM). The GLCM window size is set to 3×3, the distance is set to 1, and the angle is set to 0°. The contrast parameter Contrast is calculated, and areas with a contrast greater than a preset threshold are identified as wrinkled areas. The pixel area of ​​each wrinkled area is measured. Multiplied by the actual area of ​​a single pixel Obtain the actual fold area; based on the grayscale difference of the fold area. Set weights , hour , hour , hour Calculate the total coverage area of ​​the tape. Count the number of pixels in all tape regions in the second acquired image, multiply by A_p, and calculate the feature value of the wrapping wrinkles. The value of W ranges from 0 to 1, and the closer it is to 0, the fewer the wrinkles.

[0048] The wrapping tightness value refers to the degree of tightness of the multi-strand yarn after the tape is wrapped, reflecting the quality of the twisting. The calculation method is as follows: calculate the theoretical twisting diameter of the multi-strand yarn before wrapping. Assuming the multiple strands are evenly distributed, and the cross-section after stranding is approximately circular, the theoretical formula for calculating the strand diameter is: ,in , The number of cable strands; the actual strand diameter of the wound cable is measured in the second acquired image. The measurement method is the same as the cable diameter measurement in step S2, that is, measuring the maximum distance between the edges of the stranded cable along the direction perpendicular to the cable axis; calculate the wrapping tightness value. , The value ranges from 0 to 1.2, with values ​​closer to 1 indicating a closer partnership.

[0049] The above steps generate a feature parameter set. Substituting it into the benchmark comparison function yields the result. The value is then used to calculate the winding deviation vector. The winding deviation vector is a three-dimensional vector, expressed as: ,in: The efficiency deviation component reflects the deviation between the winding efficiency and the ideal state. The calculation formula is as follows: , The theoretical benchmark is used to compare function values. The value range is 0-1; This is the tension deviation component, reflecting the deviation in tape tension. It is related to the wrinkle characteristic value, the number of cable strands, and the diameter. The calculation formula is as follows: ,in and For normalization, N is the number of cable strands, and D is the cable diameter. The value range is 0-1; The stability deviation component reflects the winding stability deviation and is related to the uniformity value, the tightness value, and the attitude distance value. The calculation formula is as follows: ,in For the normalization of attitude distance values, The value range is 0-1.

[0050] The winding execution module is equipped with an execution instruction information library, which stores a number of winding execution instructions. Each winding execution instruction is indexed by a vector matching condition. The winding execution module matches the corresponding winding execution instruction according to the winding deviation vector to generate a winding execution instruction set to control the actions of the first and second camera positions. The winding execution instruction set includes the winding execution instructions corresponding to each attitude angle. The construction of the execution instruction information library is based on vector matching conditions. First, the three components of the winding deviation vector are... , , Each component is divided into three deviation intervals: low deviation interval (0≤ΔV≤0.2), medium deviation interval (0.2<ΔV≤0.5), and high deviation interval (0.5<ΔV≤1). The combinations of these three intervals form 27 vector matching conditions (3×3×3). Each matching condition corresponds to a set of winding execution instructions. The parameters in the instructions are calibrated experimentally. The experimental method is as follows: three different cable specifications are selected (specification 1: N=2, D=1mm; specification 2: N=3, D=1.2mm; specification 3: N=4, D=1.5mm). Ten trial windings are performed for each cable specification. The winding effect after adjusting the rotational speed ω of the first drive mechanism, the conveying speed v of the second drive mechanism, and the tension T of the conveyor belt at different ΔV values ​​is recorded. The parameter that makes the benchmark comparison function value F closest to 1 is selected as the instruction parameter corresponding to that matching condition. Some matching conditions and corresponding instructions in this embodiment are as follows:

[0051] Matching condition 1: ΔV1∈low deviation, ΔV2∈low deviation, ΔV3∈low deviation, corresponding instruction 1: ω=100r / min, v=5mm / s, T=5N;

[0052] Matching condition 2: ΔV1∈Medium deviation, ΔV2∈Low deviation, ΔV3∈Medium deviation, corresponding to instruction 2: ω=90r / min, v=4.5mm / s, T=5.5N;

[0053] Matching condition 3: ΔV1∈High deviation, ΔV2∈Medium deviation, ΔV3∈High deviation, corresponding to instruction 3: ω=80r / min, v=4mm / s, T=6N.

[0054] By calculating the winding deviation vector, we can obtain the information on the deviation during trial winding. By correcting the information on the deviation during trial winding, we can obtain the optimal winding execution command. It should be noted that the winding execution command is a dynamic output. For example, the applied force and speed at each angle may be different. At the same time, the winding command may also be different depending on the actual triggering conditions, so as to ensure the reliability of winding.

[0055] The generation process of the winding execution instruction set is as follows: First, the winding execution module receives the winding deviation vector ΔV sent by the image analysis module; second, the interval judgment unit inside the module performs interval judgment on ΔV1, ΔV2, and ΔV3 respectively to determine the corresponding vector matching conditions; third, the module's instruction calling unit retrieves the corresponding winding execution instruction from the execution instruction information database according to the matching conditions; finally, the module's instruction set generation unit splits the retrieved instructions according to the attitude angle to generate the winding execution instruction set. The attitude angle is defined as a unit of 10° rotation of the winding frame (36 units in total for 360°). Each unit corresponds to a set of ω, v, and T parameters. The splitting is based on the changing patterns of tape tension and cable position during the winding process. Experiments show that adjusting the parameters every 10° can effectively compensate for winding deviations and ensure winding accuracy. For example, when the winding frame rotates from 0° to 10°, the first set of parameters in the instruction set is used; when it rotates from 10° to 20°, the second set of parameters is used, and so on, until a 360° rotation is completed.

[0056] The execution process of the instruction set is as follows: The control system converts the winding execution instruction set into control signals for the first motor, the second motor, and the belt tension controller. The control signal for the first motor is used to regulate its speed via a frequency converter, and the control signal for the second motor is used to regulate its conveying speed via a servo driver. The belt tension controller adjusts the tension of the belt at the workstation according to the instructions. During execution, the control system collects motor speed and position signals in real time through an encoder and compares them with the parameters in the instruction set. If the deviation exceeds the allowable range, a correction signal is sent to adjust the motor action, forming a closed-loop control to ensure execution accuracy. Those skilled in the art can optimize control performance and reduce deviations by adjusting the parameters of the frequency converter and servo driver.

[0057] In this embodiment, the first drive mechanism 22 provides rotational power to the wire clamp 24, and the second drive mechanism 32 provides rotational power to the two conveying roller assemblies 31 to transmit the multi-strand wire outward. The second drive mechanism 32 also provides opposing or reverse motion forces to the two conveying roller assemblies 31 in the height direction to position the multi-strand wire being conveyed. At the same time, the rotational force provided by the first drive mechanism 22 and the linear transmission force provided by the second drive mechanism 32 are also used to wind the tape along the discharge direction of the multi-strand wire into the double-strand wire in a multi-turn winding manner, so that the double-strand wire is subjected to multiple forces and twisted together, thereby improving the quality of wire twisting.

[0058] In addition, the first station 2 of this tape winding machine is equipped with an intelligent control function to control the rotation number of the first drive mechanism 22. The first station 2 also features a display panel and operation buttons. Users input commands via the buttons to control the rotation number of the motor within the first drive mechanism 22, which in turn controls the rotation number of the winding frame 23. Ultimately, this effectively controls and sets the rotation number of the multi-strand wire driven by the wire clamp 24, thereby controlling the winding stroke of the tape onto the multi-strand wire. This achieves intelligent and effective control, improving work efficiency. For directional output of the multi-strand wire, the second drive mechanism 32 at one station, in conjunction with the upper and lower sets of conveyor roller assemblies 31, unifies the guidance and positioning of the multi-strand wire output.

[0059] In another implementation, such as Figures 2 to 4 As shown, the first machine position 2 has an assembly cavity 26, which communicates with the wire hole 21. The first drive mechanism 22 includes several positioning wheels 221 mounted around the wire hole 21 in the assembly cavity 26 and a power output wheel 222 assembled between the positioning wheels 221. A first motor 27 is also installed in the assembly cavity 26. A conveyor belt 28 is mounted on the power output shaft of the first motor 27 via pulleys. The other end of the conveyor belt 28 is driven and connected to the power output wheel 222 after being directionally transmitted through all the positioning wheels 221. The end of the winding frame 23 away from the wire clamp 24 is fixed to the power output wheel 222. The first motor 27 drives the conveyor belt 28, which in turn drives the power output wheel 222, causing the power output wheel 222 to rotate between all the positioning wheels 221. Placing the first motor 27 in the assembly cavity 26 of the first machine position 2 and on the vertical side of the wire hole 21 saves space. The control system, located in the assembly cavity 26, controls the speed and number of revolutions of the first motor 27. Multiple positioning wheels 221 are arranged in a circular array around and close to the power output wheel 222, guiding the conveyor belt 28 onto it. This increases the friction area between the conveyor belt 28 and the power output wheel 222, improving the rotational stability of the power output wheel 222 and allowing for more precise control over the number of revolutions it drives the winding frame 23 to rotate.

[0060] In another implementation, such as Figure 1 As shown, one end of the winding frame 23 fixed to the power output wheel 222 is perpendicular to the power output wheel 222. A bent portion 231 inclined towards the axis of the wire hole 21 is provided outward from the fixed end of the winding frame 23. An assembly portion 232 coinciding with the axis of the wire hole 21 is provided further outward from the bent portion 231 of the winding frame 23. The wire clamp 24 is fixed on the assembly portion 232, so that the clamp 241 always rotates about the axis of the wire hole 21. The tape station 25 is set on the bent portion 231, so that the tape station 25 is offset from the axis of the wire hole 21. The winding frame 23 is mounted on the power output wheel 222 in this way for several reasons: first, it establishes a tape station 25 for placing the roll tape; second, it establishes a path for conveying the tape in the direction of the release end clamp 24; third, the bending part 231 on the winding frame 23 shortens the distance between the clamp 24 and the wire hole 21, thereby bringing the distance between the two conveyor roller assemblies 31 and the wire hole 21 closer, reducing the length of the equipment in the feeding and discharging directions and saving installation space; and fourth, when the release end of the tape is fed towards the clamp opening 241 of the clamp 24, it will not obstruct the feeding of multi-strand wires towards the clamp opening 241.

[0061] In another implementation, such as Figure 4 , Figure 5 as well as Figure 7 As shown, the upper and lower opposing surfaces of the clamp 241 are provided with relatively protruding arc-shaped extrusion parts 2411, and a gap is left between the two arc-shaped extrusion parts 2411, which corresponds to the discharge direction of the conveyor belt station 25. The release end of the conveyor belt enters the gap between the two arc-shaped extrusion parts 2411. The feed side of the gap is the introduction position of the release end of the conveyor belt, and the gap coincides with the axis of the wire hole 21, which forms a winding condition with the linear output multi-strand wire. The multi-strand wire is introduced from the front side of the gap between the two conveyor roller assemblies 31, while the conveyor belt is wrapped around the linear output multi-strand wire by side wrapping as the wire clamp 24 rotates. The structure is reasonable.

[0062] In another implementation, such as Figure 3 , Figure 6As shown, the second mounting position 3 is provided with an ear-type assembly facing the wire outlet side of the clamp 24. This embodiment discloses one implementation of the second drive mechanism 32, specifically: the second drive mechanism 32 includes two upper and lower toothed gears 321 that are rotatably connected in the ear-type assembly, an electric cylinder 322 fixed to the top of the second mounting position 3, and a rack 323 mounted on the actuating rod of the electric cylinder 322. The rack 323 enters the second mounting position 3 and meshes with one of the toothed gears 321. The toothed parts of the two toothed gears 321 mesh together. A rotating seat is installed on the non-meshing part of each of the two toothed gears 321. A vertically parallel pressure bar is rotatably mounted in each of the two rotating seats. The rod 324 and the conveyor roller assembly 31 include a roller 311 installed at one end of the two pressure rods 324, forming a rolling gap 326 between the two rollers 311. The rolling gap 326 corresponds to the wire outlet side of the clamp 241. A second motor 328 is fixed on the second machine position 3. Two intermediate gears 329 are installed on the outer side of the ear-type assembly. The upper intermediate gear 329 meshes with the upper driven gear 327, and the lower intermediate gear 329 meshes with the lower driven gear 327. A drive gear 3281 is installed on the power output shaft of the second motor 328, and the drive gear 3281 meshes with the upper intermediate gear 329.

[0063] In this embodiment, the electric cylinder 322 is energized to drive the rack 323 to descend. The rack 323 drives the bottom toothed gear 321 to rotate counterclockwise, and the bottom toothed gear 321 drives the top toothed gear 321 to rotate clockwise. Thus, the upper and lower toothed gears 321 drive the upper and lower rotating seats to deflect in opposite directions. The two rotating seats drive the upper and lower pressure rods 324 to deflect in opposite directions. The upper and lower pressure rods 324 drive the two grinding wheels 311 to deflect in opposite directions, forcing the two grinding wheels 311 to move closer together to form a positioning and output condition for the multi-strand wire output side.

[0064] In addition, a driven gear 327 that can mesh with each other is installed on the other end of each of the two pressure rods 324 away from the grinding wheel 311. When the upper pressure rod 324 deflects upward and the lower pressure rod 324 deflects downward, the two grinding wheels 311 are pulled away from each other (when the tape is wrapped and the wire is taken out). At this time, the two driven gears 327 follow the two pressure rods 324 and are pulled away from each other in opposite directions. When the upper pressure rod 324 deflects downward and the lower pressure rod 324 deflects upward, the two grinding wheels 311 are brought closer to each other (when the tape is wrapped and the wire is taken out). At this time, the two driven gears 327 follow the two pressure rods 324 and are pulled away from each other in opposite directions. As the wires are pulled closer and engaged, the second motor 328 starts, driving the drive gear 3281 to rotate. The drive gear 3281 meshes with the intermediate gear 329 to rotate, which in turn drives a driven gear 327 to rotate. This driven gear 327 then drives another driven gear 327 to rotate. These two driven gears 327 simultaneously drive the pressure rod 324 to rotate, which in turn drives the two rollers 311 at the other end to rotate. These rollers 311 then press the double-stranded wire outward in a straight line, coordinating with the tape to wind around the double-stranded wire, thus completing the multi-stranded wire stranding operation.

[0065] like Figure 3 , Figure 4 As shown, the first machine position 2 is provided with an L-shaped wire material area 29. The wire hole 21 is connected to the wire material area 29. In actual use, the wire material area 29 is a storage area for multi-strand wires. The output end of the multi-strand wire is passed through the wire hole 21 and enters the clamp 241, while the retention end of the multi-strand wire remains in the wire material area 29. As the multi-strand wire is output outward, its retention end eventually passes through the wire hole 21 and enters the winding side. The rear side of the wire material area 29 is the display and control area of ​​the first machine position 2, and the control system is set in the control area.

[0066] Where relational terms such as "first" and "second" appear in this document, they are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0067] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high precision stroke controllable tape winding machine, characterized in that: The utility model relates to a cable winding machine, including base (1), be equipped with first machine position (2) and second machine position (3) on base (1), be equipped with wire hole (21) on first machine position (2), be equipped with first drive mechanism (22) in wire hole (21), be equipped with winding frame (23) on first drive mechanism (22), winding frame (23) is fixed with wire clamp (24), the mouth (241) of wire clamp (24) coincides on the axis of wire hole (21), be equipped with adhesive tape station (25) on winding frame (23) corresponding in the oblique position of mouth (241), second machine position (3) is located wire clamp (24) side, be equipped with two conveying roller assembly (31) of up and down on second machine position (3), be equipped with second drive mechanism (32) on second machine position (3), first drive mechanism (22) drive winding frame (23), and by winding frame (23) drive adhesive tape station (25) and wire clamp (24) rotate between two conveying roller assembly (31), second drive mechanism (32) drive two conveying roller assembly (31) rotate relative to the wire outlet direction of wire clamp (24), second drive mechanism (32) can also drive two conveying roller assembly (31) in height direction each other or reverse motion.

2. The high precision stroke controllable tape winding machine according to claim 1, characterized in that, Also including a control system, the control system includes a trial winding module, an image analysis module, and a winding execution module; The trial winding module is configured with a winding simulation instruction, which is used for the first machine position and the second machine position to cooperate to make the cable to be wound to a first state and then restore to an initial state; The image analysis module is configured with an image analysis strategy, which is used to analyze image information of the cable to be wound and generate a winding deviation vector; The winding execution module is configured with an execution instruction information library, which stores a plurality of winding execution instructions, each winding execution instruction is indexed by a vector matching condition, and the winding execution module matches a corresponding winding execution instruction according to the winding deviation vector to generate a winding execution instruction set to control the actions of the first machine position and the second machine position, and the winding execution instruction set includes a corresponding winding execution instruction at each attitude angle.

3. The high precision stroke controllable tape winding machine according to claim 2, characterized in that, The image analysis strategy includes the following steps: Step S1, obtaining a first acquisition image in an initial state to obtain a second acquisition image in a first state; Step S2, generating a reference parameter set from the first acquisition image according to a predetermined reference recognition algorithm, and generating a corresponding reference comparison function according to the reference parameter set, the reference parameter set including cable strand count, cable diameter, and cable attitude distance value; Step S3, generating a feature parameter set from the second acquisition image according to a predetermined feature extraction algorithm, and bringing the feature parameter set into the reference comparison function to generate a winding deviation vector, the feature parameter set including adhesive tape overlap area, winding uniformity value, winding wrinkle characteristic value, and winding close value.

4. The high precision stroke controllable tape winding machine according to claim 1, characterized in that, The first machine position (2) is internally provided with an assembly cavity (26), the assembly cavity (26) is communicated with the wire hole (21), the first driving mechanism (22) comprises a plurality of positioning wheels (221) installed in the assembly cavity (26) around the wire hole (21) and a power output wheel (222) assembled between a plurality of the positioning wheels (221), a first motor (27) is also installed in the assembly cavity (26), a conveying belt (28) is installed on the power output shaft of the first motor (27) through a pulley, the other end of the conveying belt (28) is drivingly connected to the power output wheel (222) after being directionally transmitted through all the positioning wheels (221), and the bobbin (23) is fixed to the power output wheel (222) away from one end where the wire clamp (24) is installed.

5. The high precision stroke controllable tape winding machine according to claim 4, characterized in that, The end of the bobbin (23) fixed to the power output wheel (222) is perpendicular to the power output wheel (222), a bending part (231) inclined to the axis direction of the wire hole (21) is provided outward from the fixed end of the bobbin (23), an assembly part (232) coinciding with the axis of the wire hole (21) is further provided outward from the bending part (231) of the bobbin (23), the wire clamp (24) is fixed to the assembly part (232), so that the clamp opening (241) is always rotated with the axis of the wire hole (21), and the adhesive tape station (25) is arranged on the bending part (231), so that the adhesive tape station (25) is deviated from the axis of the wire hole (21).

6. The high precision stroke controllable tape winding machine according to claim 5, characterized in that, Opposite arc-shaped extrusion parts (2411) are arranged on the upper and lower opposite surfaces of the clamp opening (241), a gap is left between the two arc-shaped extrusion parts (2411), and the gap corresponds to the discharging direction of the adhesive tape station (25).

7. The high precision stroke controllable tape winding machine according to claim 6, characterized in that, The second machine position (3) is provided with an ear-shaped assembly part facing the wire outlet side of the wire clamp (24), the second driving mechanism (32) comprises two upper and lower toothless gears (321) adapted in the ear-shaped assembly part, an electric cylinder (322) fixed to the top of the second machine position (3), and a rack (323) installed on the action rod of the electric cylinder (322), the rack (323) enters the second machine position (3) and is engaged with one of the toothless gears (321), the toothed parts of the two toothless gears (321) are engaged together, a rotating seat is installed on the non-engagement part of each of the two toothless gears (321), and one upper and lower parallel pressing rod (324) is adapted in each of the two rotating seats, the conveying roller assembly (31) comprises a roller (311) installed at one end of the two pressing rods (324), a rolling gap (326) is formed between the two rollers (311), and the rolling gap (326) corresponds to the wire outlet side of the clamp opening (241).

8. The high precision stroke controllable tape winding machine according to claim 7, characterized in that, Two said pressure rod (324) away from the other end of the roller (311) on each installation can be meshed with a driven gear (327), said second machine (3) is fixed with a second motor (328), the outside of the ear type assembly part is installed with two intermediate gear (329) up and down, the upper said intermediate gear (329) and the upper said driven gear (327) into engagement, the lower said intermediate gear (329) and the lower said driven gear (327) into engagement, the power output shaft of said second motor (328) is installed with a driving gear (3281), said driving gear (3281) is engaged on the upper said intermediate gear (329).

9. The high precision stroke controllable tape winding machine according to claim 8, characterized in that, The first machine (2) is provided with an L-shaped wire area (29), and the wire hole (21) is communicated with the wire area (29).

Images