Multi-strand wire core synchronous paying-off control method and system in cable forming process

Abstract

The invention relates to the technical field of cable production, in particular to a multi-strand wire core synchronous paying-off control method and system in the cable forming process. Comprising the steps of collecting data in real time through a speed and tension sensor, adjusting the rotating speed of a motor based on feedback to correct tension deviation, dynamically matching the speed of multiple strands of wire cores through an intelligent algorithm, dynamically compensating the diameter of a wire coil to stabilize the speed and tension, and carrying out real-time fault diagnosis and early warning. The system is composed of a pay-off rack, a tension and speed sensor, an independent driving motor, a PLC, an industrial computer controller, a man-machine interaction interface and a communication module, all the parts cooperate to achieve closed-loop control, the cable core speed deviation is smaller than or equal to + / -0.5%, the tension deviation is smaller than or equal to + / -2N, the cable roundness error is smaller than or equal to + / -0.2 mm, the production efficiency is improved by 30% or above, the defective rate is remarkably reduced, and the production cost is reduced. The device is suitable for production of cables of different specifications.

Description

[0001] The application relates to the technical field of cable production, and in particular to a multi-strand core synchronous pay-off control method and system in a cable forming process. BACKGROUND

[0002] In a cable manufacturing process, cable forming is a key link, and the quality directly affects the electrical performance, mechanical performance and service life of the cable. Multi-strand core synchronous pay-off, as a basic process of cable forming, plays a decisive role in ensuring the quality of the cable by realizing precise control. The precise control is not only related to the arrangement regularity of the cores, but also closely related to the overall structural stability and signal transmission reliability of the cable. SUMMARY

[0003] In the traditional cable forming process, the multi-strand core synchronous pay-off control has always been a problem plaguing the industry. Common control methods often rely on simple mechanical structures or open-loop control methods, and it is difficult to realize high-precision synchronous pay-off. In actual production, due to the lack of effective cooperation between pay-off mechanisms, the pay-off speeds of different cores often differ, resulting in uneven tension of the cable during the cable forming process. This uneven tension not only causes the relative positions of the cores to deviate, affecting the roundness of the cable, but also may cause some cores to be subjected to excessive force, causing wear or even damage to the core insulation layer, thereby reducing the electrical insulation performance of the cable, increasing the risk of electric leakage, and seriously affecting the quality and service life of the cable.

[0004] In order to solve the technical problems of low control precision, inability to adapt to complex production environments, and high equipment maintenance costs in the prior art, the technical scheme adopted by the application is as follows:

[0005] A preparation method of a bending-resistant sensor cable for a high-speed train set, comprising the following steps:

[0006] (1) A high-precision speed sensor is installed on the pay-off path of each core. According to the specifications and process requirements of the cable to be produced, various parameters are set, and the pay-off speed data of the cores are collected in real time;

[0007] Among them, the parameters are preset, the core with the largest diameter and the hardest material in the cable forming is selected as the reference core, the cable forming process parameters, the cable forming speed V and the twisting pitch P, and the target pay-off speed of the reference core are inputted.

[0008]

[0009] The diameter of the reference core is D; the diameters of the other cores are D1, D2, D3, D4 and D5; the material elastic modulus of the reference core is E; the material elastic modulus of the other cores is E1, E2, E3, E4 and E5; the target pay-off speed of the reference core is V; and the target pay-off speeds of the other cores are V1, V2, V3, V4 and V5.

[0010] ​​

[0011] Material correction factor; copper 1.0, aluminum 0.85, and alloy 0.92;

[0012] Target tension:

[0013]

[0014] N, and the initial diameter of each wire coil is input ;;

[0015] (2) Real-time parameter acquisition: through speed sensors, tension sensors, and laser displacement sensors, data is synchronously collected to obtain the real-time laying speed of each wire core Real-time tension Real-time radius of the wire coil Real-time winding diameter Real-time winding diameter Real-time winding diameter

[0016] (3) Real-time monitoring of the tension of each wire core using tension sensors. When the tension deviates, the control system automatically adjusts the rotation speed of the driving motor of the laying device according to the preset tension threshold and control algorithm, changing the laying tension

[0017] Wherein, the speed deviation is calculated as:

[0018]

[0019] Tension deviation:

[0020]

[0021] Winding diameter deviation:

[0022]

[0023] The theoretical winding diameter is calculated as:

[0024] )

[0025] Wherein, L i = , dt is the laying length, and the comprehensive deviation coefficient is obtained through a weighted algorithm:

[0026]

[0027] When the deviation is greater than 2%, the system is triggered to automatically adjust

[0028] (4) According to the real-time speed data of the core, the diameter change of the reel, the cable material characteristics and other factors, the optimal laying speed required by each core is automatically calculated, and the motor speed is adjusted in real time to realize the synchronous laying of multiple cores;

[0029] Wherein, the motor speed correction amount:

[0030]

[0031] Wherein, is a proportional coefficient, is an integral coefficient, is a differential coefficient, , , With Dynamic adjustment, When Increase by 20%, When

[0032]

[0033] According to Real repair target speed:

[0034] ;

[0035] (5) By establishing a mathematical model between the diameter of the reel and the laying speed and tension, the change of the diameter of the reel is calculated in real time, and the speed of the laying motor is dynamically compensated according to the calculation result;

[0036] Real-time analysis and processing of sensor data, timely detection of abnormal conditions in the laying process, such as core breakage, motor failure, sensor failure, etc., and sending early warning signals,

[0037] (6) When >8% or >10%, trigger audible and light alarms and reduce the cable speed to 50%, and if the deviation is not alleviated for 3 seconds, the machine will automatically stop and record data

[0038] Further: in step (4) The initial value is 0.8-1.2, The initial value is 0.05-0.1, The initial value is 0.1-0.2, Each increase by 1%, Synchronous increase by 5%, , Synchronous increase by 3%.

[0039] Further: the laying control system comprises the following multiple unit data modules:

[0040] (1) a pay-off stand for carrying the wire reels and providing the basic support for the wire core pay-off;

[0041] (2) a plurality of speed sensors, tension sensors, and laser displacement sensors installed on the pay-off path of each wire core for real-time monitoring of the tension and pay-off speed of the wire core;

[0042] (3) a plurality of drive motors, each wire core pay-off device is equipped with an independent drive motor, and the pay-off speed of the wire core is adjusted by controlling the rotation speed of the motor;

[0043] (4) a controller as the core control unit of the entire system, responsible for collecting sensor data, running control algorithms, sending control instructions, and implementing overall coordination and management of the system;

[0044] (5) a human-computer interaction interface for operators to set parameters, monitor states, diagnose faults, and control operations of the system;

[0045] (6) a communication module for realizing data communication between the controller and various sensors, drive motors, and other devices.

[0046] Further: a multi-strand wire core synchronous pay-off control system is set up during the cable cabling process, comprising

[0047] (1) a pay-off stand for carrying the wire reels and providing the basic support for the wire core pay-off;

[0048] (2) a plurality of tension sensors and laser displacement sensors installed on the pay-off path of each wire core for real-time monitoring of the tension of the wire core;

[0049] (3) a plurality of drive motors, each wire core pay-off device is equipped with an independent drive motor, and the pay-off speed of the wire core is adjusted by controlling the rotation speed of the motor;

[0050] (4) a controller as the core control unit of the entire system, responsible for collecting sensor data, running control algorithms, sending control instructions, and implementing overall coordination and management of the system;

[0051] (5) a human-computer interaction interface for operators to set parameters, monitor states, diagnose faults, and control operations of the system;

[0052] (6) a communication module for realizing data communication between the controller and various sensors, drive motors, and other devices.

[0053] Further: the pay-off stand is adapted to the wire core diameter range of 0.5-10mm, and the initial diameter of the reel is in the range of 300-800mm.

[0054] Further, the human-computer interaction interface adopts a touch screen display to present an operation interface in a graphical design.

[0055] Further, the communication module adopts an Ethernet communication protocol with high speed and reliability, and has good anti-interference ability and stability.

[0056] Further, the controller adopts a programmable logic controller (PLC) with powerful data processing ability and fast operation speed.

[0057] The present application has the following beneficial effects:

[0058] The present application has the following beneficial effects: BRIEF DESCRIPTION OF DRAWINGS

[0059] Figure 1 Fig. 1 is a control flow chart of a cable cabling process multi-strand synchronous pay-off control method and system according to the present application. DETAILED DESCRIPTION

[0060] The present application will be further described below in conjunction with specific embodiments. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of the present application.

[0061] Embodiment 1

[0062] The cable cabling process multi-strand synchronous pay-off control flow logic of the present application is as follows:

[0063] S1: system initialization is completed;

[0064] S2: an operator sets pay-off speed, tension threshold and other parameters through a human-computer interaction interface;

[0065] S3: The tension sensor and the speed sensor collect the tension and speed data of the core in real time and transmit them to the controller;

[0066] S4: The controller filters the data, calculates the speed deviation Δv and the tension deviation ΔF, and judges whether it exceeds the allowed range (speed deviation ≤ ±0.5%, tension deviation ≤ ±2N);

[0067] S5: If it exceeds the range, it enters, calculates the speed correction of the driving motor through the adaptive control algorithm;

[0068] S6: The driving motor responds to the instruction to adjust the speed, so that the core parameters return to the normal range;

[0069] S7: At the same time, continuous fault diagnosis is carried out, when detecting the core breakage, motor failure and other abnormalities;

[0070] S8: Sound and light warning is issued, if it is not restored within 3 seconds, it will automatically stop.

[0071] Example two

[0072] A kind of cable cabling process multi-strand core synchronous pay-off control method and system, comprising the following specific implementation steps:

[0073] 1. Equipment installation and debugging

[0074] First, install the pay-off rack, tension sensor, driving motor, controller, human-computer interaction interface and communication module, etc. Ensure that the pay-off rack is installed stably, the installation position of each reel is accurate, the tension sensor and the speed sensor are installed on the appropriate pay-off path to ensure that the tension and speed data of the core can be accurately collected, the driving motor is connected firmly with the pay-off device, and the motor's steering and speed regulation function is normal, the controller and each device realize reliable data communication through the communication module, after installation, the whole system is comprehensively debugged, and the working state and communication connection of each device are checked.

[0075] 2. Parameter setting and initialization

[0076] The operator enters the system setting interface through the human-computer interaction interface, sets various parameters according to the cable specifications and process requirements to be produced, these parameters include pay-off speed, tension threshold, control algorithm parameters, reel initial diameter, etc. For a certain specific specification of cable, set the pay-off speed to 10 meters per minute, the tension threshold to 50N-60N, select the appropriate control algorithm according to the characteristics of the cable, and input the initial diameter data of the reel. After setting, the system performs initialization operation, loads each parameter into the controller, and makes the system enter the preparation state.

[0077] 3. Core pay-off operation

[0078] After everything is ready, start the wire releasing device. The core is released from the reel, passes through the tension sensor and speed sensor, the sensor collects the tension and speed data of the core in real time, and transmits the data to the controller through the communication module. The controller adjusts the speed of each drive motor in real time according to the preset control algorithm and the collected data. When the controller detects that the tension of a core is higher than the set value, it immediately sends an instruction to the drive motor corresponding to the core to reduce the motor speed, thereby reducing the wire releasing speed and restoring the tension to the normal range. Conversely, when the tension is lower than the set value, increase the motor speed to increase the wire releasing speed.

[0079] 4. Real-time monitoring and adjustment

[0080] During the wire releasing process, the operator monitors the wire releasing speed, tension, reel diameter change and other key parameters in real time through the human-machine interface. At the same time, the fault diagnosis and early warning function of the system continues to run, analyzes and processes the sensor data, and immediately issues a warning signal and displays the fault information on the human-machine interface once an abnormal situation is found, such as excessive or insufficient core tension, abnormal wire releasing speed, motor failure, etc. The operator adjusts and handles the situation in a timely manner according to the warning information to ensure the safety and stability of the wire releasing process.

[0081] 5. Production completion and equipment maintenance

[0082] When the cable production task is completed, stop the operation of the wire releasing device and each equipment, clean and maintain the equipment, check the wear of each part, and replace the severely worn parts in time.

[0083] Finally, it should be noted that the above description is only a preferred embodiment of the present application and is not intended to limit the present application. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent replacements to some technical features. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A method for controlling the simultaneous laying of a plurality of cores in a cable laying process, characterized in that It comprises the following steps: (1) Install high-precision speed sensors on the laying path of each core, set parameters according to the cable specifications and process requirements to be produced, and collect real-time laying speed data of the core; Wherein, the parameters are preset, the largest diameter and hardest material core in the cabling is selected as the reference core, and the cabling process parameters, cabling speed V, and twisting pitch P are input, and the target laying speed of the reference core is: Reference line core diameter; other line core diameters Material modulus of elasticity Target payout speed of each line core: Material correction factor; 1.0 for copper, 0.85 for aluminum, and 0.92 for alloys; Target tension: Units are N, while inputting initial diameter of each wire coil ; (2) Real-time parameter acquisition, through speed sensor, tension sensor, laser displacement sensor to collect data synchronously, to get the real-time laying speed of each wire core Real-time tension Real-time radius of the reel Real-time reel diameter conversion Real-time reel diameter conversion Real-time reel diameter conversion (3) Real-time monitor the tension of each core by using the tension sensor, when the tension deviates, the control system automatically adjusts the speed of the driving motor of the laying device according to the preset tension threshold and control algorithm to change the laying tension; Wherein, the speed deviation is calculated as: Tension deviation: Rolling diameter deviation: Theoretical coil diameter is calculated as: ） wherein dt is the length of the wire, and the overall deviation coefficient is obtained by a weighting algorithm: > Trigger system automatic adjustment at 2% (4) According to the real-time speed data of the core, the diameter change of the reel, the material characteristics of the cable and other factors, the optimal laying speed required by each core is automatically calculated, and the motor speed is adjusted in real time to realize the synchronous laying of multiple cores; Wherein, the motor speed correction amount is: Wherein, is a proportional coefficient, is an integral coefficient, is a differential coefficient, , , With dynamic adjustment, When > 5% Increase by 20%, When > 3%, the magnetic powder brake current is adjusted in linkage According to Actual correction target rotational speed: (5) By establishing a mathematical model between the reel diameter and the laying speed and tension, the change of the reel diameter is calculated in real time, and the speed of the laying motor is dynamically compensated according to the calculation result; (6) Real-time analysis and processing of sensor data, timely detection of abnormal conditions in the laying process such as core breakage, motor failure, sensor failure, etc., and sending of early warning signals, wherein, when > 8% or > 10%, a sound and light alarm is triggered and the cabling speed is reduced to 50% for 3 seconds. If the deviation is not alleviated, the machine is automatically stopped and data is recorded.

2. The method of claim 1, wherein: In step (4) The initial value is taken as 0.8-1.2, The initial value is taken as 0.05-0.1, The initial value is taken as 0.1-0.2, Every 1% increase, Synchronous increase of 5%, 、 Synchronous increase of 3%.

3. The multi-strand core simultaneous pay-off control system for cabling process of a cable as claimed in claim 1, wherein: It comprises the following multiple unit data modules: (1) Laying rack, used to carry the reel and provide basic support for the laying of the core; (2) Multiple speed sensors, tension sensors and laser displacement sensors, respectively installed on the laying path of each core, for real-time monitoring of the tension and laying speed of the core; (3) Multiple driving motors, each core laying device is equipped with an independent driving motor, the laying speed of the core is adjusted by controlling the speed of the motor; (4) Controller, as the core control unit of the whole system, responsible for collecting sensor data, running control algorithm, sending control instructions and realizing the overall coordination and management of the system; (5) Human-computer interaction interface, used for operators to set parameters, monitor status, diagnose faults and operate control of the system; (6) Communication module, used for data communication between the controller and various sensors, driving motors and other devices.

4. The multi-strand core simultaneous pay-off control system for cabling process of the cable according to claim 4, characterized in that: The laying rack is suitable for core diameter range of 0.5-10mm, and the initial diameter of the reel is 300-800mm.

5. The multi-strand core simultaneous pay-off control system for cabling process of the cable according to claim 4, characterized in that: The human-computer interaction interface uses a touch screen display to present the operation interface in a graphical design.

6. The multi-strand core simultaneous pay-off control system for cabling process of the cable of claim 4, wherein: The communication module uses high-speed and reliable communication protocol Ethernet, with good anti-interference ability and stability.

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