Counting system and method for cable coil processing

Abstract

The application discloses a counting system and method for cable coil processing, and relates to the technical field of industrial manufacturing, and comprises the following steps: establishing a cable coil counting rhythm file, recording the number of turns trigger rhythm, the tension waveform and the change node of the wire arrangement path, and generating a traceable counting rhythm sequence; based on the counting rhythm sequence, the abnormal repeated track is phase compared, the time dislocation of the counting signal is detected when the speed changes and the path overlaps, and a blank time area containing an abnormal section is generated. Through the establishment of the counting rhythm file, the application realizes the multi-dimensional dynamic correlation of the number of turns rhythm, the tension waveform and the wire arrangement path, ensures the continuous and stable counting during the winding process; and through the double-phase counting mechanism, the main counting and the standby counting are alternately triggered, the adaptive switching is realized when the winding is stacked or turned back, the counting is ensured to be accurate and reliable, and the processing out of control and the length out of limit are avoided.

Description

Technical Field

[0001] This invention relates to the field of industrial manufacturing technology, and more specifically to a counting system and method for processing cable coils. Background Technology

[0002] Cable coil processing counting refers to the process control behavior of continuously identifying, recording, and judging key processing quantity parameters formed during the cable production process, specifically during the winding, coiling, or unwinding stages. Its core object is not simply quantity statistics, but rather the synchronous perception and orderly calibration of changes in the number of turns, cumulative length, cycle time, and process node status during coil formation. Specifically, this counting process runs through continuous processing stages such as cable laying, guiding, winding, forming, and shaping. By tracking the wire's movement trajectory, rotation rhythm, position changes, and processing cycle time, each winding action, each length formation process, and each forming cycle has an identifiable quantity marker. This provides fundamental data support for subsequent length control, specification consistency judgment, batch management, and processing rhythm control, achieving orderly organization and precise control of the coil processing process.

[0003] The existing technology has the following shortcomings:

[0004] In existing technologies, the counting process for cable coil processing typically relies on the periodic motion characteristics generated during coil winding to determine the effective number of turns. When coils overlap and accumulate at a certain local location, subsequent cables tend to continue stacking along the existing overlap trajectory, weakening the coil's shape and significantly diminishing or even eliminating the motion characteristics originally used to trigger counting. In this situation, the counting device may fail to recognize new winding actions for an extended period, causing the counting results to stop updating, while the winding equipment continues to feed and wind wire according to the predetermined processing rhythm. Because the counting results fail to reflect the actual processing progress in a timely manner, the system may misjudge that the coil has not reached the set quantity or length, thus continuing to execute processing operations and ultimately forming abnormal coils with an actual length far exceeding the design requirements. Such anomalies are not easily detected in time during the coil forming stage and can easily lead to safety hazards during handling, stacking, or transportation due to increased weight and uncontrolled volume.

[0005] The information disclosed in the background section is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide a counting system and method for cable coil processing to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a counting method for cable coil processing, comprising the following steps:

[0008] Establish a cable coil counting rhythm archive, record the number of turns triggering beats, tension waveforms, and changes in the winding path, and generate a traceable counting rhythm sequence to identify abnormal repetitive trajectories formed during the cable coil winding process;

[0009] Phase comparison of abnormal repeating trajectories is performed based on the counting rhythm sequence. When the speed change overlaps with the path, the time misalignment of the counting signal is detected, and a blank time area containing the abnormal segment is generated as a reference window for subsequent analysis.

[0010] Based on the blank time zone, conduct joint analysis of shape and tension, track the slight fluctuations in the shape of the cable coil and compare the tension fluctuation characteristics to determine the stagnation position of the counting signal and output the stop counting area identifier;

[0011] The counting triggering order was rearranged based on the stop counting area identifier, reverse markers were set on abnormal repeating paths and temporary bypass path detection was introduced to form a new draft counting execution order;

[0012] The rhythmic counting correction is implemented according to the draft counting execution order. The main counting signal and the backup counting signal are triggered alternately through a two-phase counting mechanism. When winding overlap is detected, the counting path is switched to the reversal path in real time to achieve continuous and accurate counting of cable coils.

[0013] Preferably, the steps for establishing the counting rhythm sequence are as follows:

[0014] When establishing a counting rhythm archive for cable coils, the real-time motion state of the cable coil winding process is continuously recorded first. The time rhythm baseline of the winding action is formed by acquiring the rotation rhythm of the winding drive end and the running beat of the conductor. The angular displacement change, translation extension and bending nodes of the conductor at different guide positions are recorded simultaneously.

[0015] After the time rhythm baseline is established, the tension waveform during the cable coil winding process is continuously acquired. The tension waveform characteristics in each beat cycle are paired and stored with the corresponding winding time node to form a mechanical response sequence with time correlation.

[0016] After establishing a correspondence between time rhythm and tension information, the changing nodes of the conductor laying path are continuously tracked, and the displacement changes, trajectory extension direction and overlapping areas are recorded as spatial joint data of beat and path.

[0017] After integrating the three types of information—time, tension, and path—the rhythm file is logically serialized and recombined according to the winding process to generate a traceable counting rhythm sequence, thereby enabling the identification of abnormal repetitive trajectories.

[0018] Preferably, when generating the counting rhythm sequence, the number of turns triggers the beat as the main time axis, the tension waveform characteristics are used as the force correlation information under the corresponding beat, and the cable path change nodes are used as the spatial identifiers corresponding to the beat, so that the counting rhythm sequence has time continuity, mechanical correlation and path traceability at the same time, thereby distinguishing between normal winding trajectory and abnormal repetitive trajectory.

[0019] Preferably, the steps for generating the blank time zone are as follows:

[0020] The time information in the counting rhythm sequence is standardized, and the number of revolutions triggering the beat is used as the time axis. The changes in tension waveform, path extension trajectory and winding direction are time-aligned to form a unified time baseline.

[0021] On a unified time baseline, the time phase of continuous winding cycles is compared zone by zone. By comparing the trigger time intervals of adjacent beat intervals, the time misalignment caused by changes in winding speed and path overlap is identified.

[0022] After identifying the time misalignment segment, a joint analysis of the tension waveform and path overlap state is performed, and the start and end points of the abnormal time period are determined based on the extension of the peak spacing and the path overlap area.

[0023] After identifying the abnormal time interval, the boundary of the time interval is extended and the structure is summarized to form a blank time area containing the abnormal segment, and then it is bound to the tension waveform characteristics, path change nodes and cycle trigger beat index.

[0024] Preferably, when forming the blank time zone, the transition beats at both ends of the time misalignment segment are extended so that the blank time zone simultaneously includes the rhythm buffer zone before the anomaly occurs and the rhythm recovery zone after the anomaly ends, thereby ensuring that the blank time zone has a complete start and end state and has continuous rhythm characteristics.

[0025] Preferably, the steps for outputting the stop measurement area identifier are as follows:

[0026] For the generated blank time zone, the spatial morphological characteristics of the cable coil are refined, and the shape change is matched with the time node of the blank time zone one by one to form the shape change curve.

[0027] Based on the changes in shape, a synchronous analysis of the tension waveform in the blank time zone is performed to match the time points of the peaks and troughs in the tension waveform with the time points of the fluctuations in the shape of the cable coil in order to determine the time misalignment interval.

[0028] Based on the correspondence between tension and shape, the internal characteristics of the blank time zone are jointly analyzed to determine the stagnation position of the counting signal in the section where the shape fluctuation and tension fluctuation change synchronously and gradually slow down.

[0029] After determining the location where the counting signal stops, the time and space information of the stopping interval are comprehensively identified to form a stopping area identifier that includes time boundaries, tension waveform segments, and shape curve segments.

[0030] Preferably, when forming the stop counting area marker, the time boundary is integrated with the tension waveform segment and the shape curve segment according to the time sequence of the rhythm file, so that the stop counting area marker has multi-dimensional correlation characteristics of time, form and mechanics, which can be used to provide a precise reference for the winding state for subsequent counting trigger sequence re-editing.

[0031] Preferably, the steps for forming the counting execution order draft are as follows:

[0032] Based on the time boundary and spatial location recorded by the stop counting area identifier, the winding rhythm before and after the stop counting area is sorted out, and the effective counting trigger signals before and after the stop counting area are extracted as the basis for reconstructing the counting trigger sequence.

[0033] Based on the baseline of the counting trigger sequence reconstruction, the abnormal repeat path is expanded and described, and reverse marker points are set on the abnormal repeat path to reflect the direction change of the wire during the winding process.

[0034] After the reverse marker points are set, a temporary bypass track detection is performed on the conductor running trajectory near the stop measurement area to form bypass track information to supplement abnormal paths.

[0035] After completing the detection of reverse marker points and temporary bypass routes, the above path information and counting trigger beats are rearranged to form a new draft counting execution order.

[0036] Preferably, the rhythmic counting correction is performed according to the draft counting execution order, and a two-phase counting mechanism is used to alternately trigger the main counting signal and the backup counting signal. The steps for switching to the foldback counting path when winding overlap occurs are as follows:

[0037] Based on the draft of the counting execution order, the counting trigger points in the winding process are loaded in a time sequence, and each counting trigger point is matched with the corresponding path direction according to the time sequence to form a continuous counting rhythm main line;

[0038] After the main counting rhythm line is established, a two-phase counting mechanism is constructed so that the main counting signal corresponds to the counting trigger of the normal winding path, and the backup counting signal corresponds to the counting trigger of the reverse path and the bypass path, forming an alternating response relationship.

[0039] During the operation of the biphase counting mechanism, the winding rhythm characteristics are tracked. When path repetition or rhythm interval extension occurs, the main counting signal is switched to the backup counting signal to maintain the continuity of the counting process.

[0040] After the signal switching is completed, the return counting path is continuously tracked, and the rhythm data generated by the backup counting signal is time-sequentially merged with the beat of the main counting signal to form a complete rhythmic counting record.

[0041] A counting system for cable coil processing includes a rhythm file creation module, an abnormal phase analysis module, a stop counting identification module, a count reprogramming module, and a rhythmic count correction module.

[0042] The rhythm profile creation module establishes a cable coil counting rhythm profile, records the number of turns triggering beats, tension waveforms, and changes in the winding path, and generates a traceable counting rhythm sequence to identify abnormal repetitive trajectories formed during the cable coil winding process.

[0043] The abnormal phase analysis module performs phase comparison on abnormal repeating trajectories based on the counting rhythm sequence. When the speed change overlaps with the path, it detects the time misalignment of the counting signal and generates a blank time area containing the abnormal segment, which is used as a reference window for subsequent analysis.

[0044] The stop counting identification module performs joint analysis of shape and tension based on the blank time zone, tracks the slight fluctuations in the shape of the cable coil and compares the tension fluctuation characteristics to determine the position where the counting signal stops and outputs the stop counting area identifier.

[0045] The counting reprogramming module rearranges the counting trigger order according to the stop counting area identifier, sets reverse markers on abnormal repeating paths and introduces temporary bypass path detection to form a new draft counting execution order;

[0046] The rhythmic counting correction module performs rhythmic counting correction according to the draft counting execution order. It alternately triggers the main counting signal and the backup counting signal through a two-phase counting mechanism. When winding overlap is detected, it immediately switches to the reversing counting path to achieve continuous and accurate cable coil counting process.

[0047] The technical effects and advantages provided by the present invention in the above technical solution are as follows:

[0048] This invention establishes a counting rhythm archive during cable coil processing, enabling multi-dimensional dynamic recording of turn trigger beats, tension waveforms, and changes in the winding path. This transforms the counting process from single-signal recognition to multi-source rhythm perception and timing correlation. This method continuously tracks coil shape and tension characteristics during winding. Even when abnormal overlap occurs in the winding trajectory, the integrity of the counting rhythm can be maintained based on the rhythm archive, effectively preventing processing loss of control due to interrupted counting signals. This ensures synchronization and consistency between winding progress and length control, improving the continuity and stability of the counting process.

[0049] This invention introduces a two-phase counting mechanism into the rhythmic counting correction, enabling alternating triggering of the main counting signal and the backup counting signal. This allows for immediate switching of the counting logic when the winding path repeats or reverses, ensuring accurate counting results even under complex operating conditions. This method enables adaptive switching of the counting signal under different path states, ensuring that every winding action of the cable coil is accurately counted. This significantly reduces the risk of length exceeding limits and turn errors, providing a highly reliable counting guarantee for the automatic control of cable coil processing. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0051] Figure 1 This is a flowchart of the counting method for cable coil processing according to the present invention.

[0052] Figure 2 This is a schematic diagram of the counting system for cable coil processing according to the present invention. Detailed Implementation

[0053] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, they are provided so that the description of this disclosure will be more complete and fully convey the concept of the exemplary embodiments to those skilled in the art.

[0054] This invention provides, for example Figure 1 The counting method shown for cable coil processing includes the following steps:

[0055] Establish a cable coil counting rhythm archive, record the number of turns triggering beats, tension waveforms, and changes in the winding path, and generate a traceable counting rhythm sequence to identify abnormal repetitive trajectories formed during the cable coil winding process;

[0056] In the cable coil processing, to generate stable and reliable basic data during the counting process, enabling continuous tracking and accurate identification of the cable coil winding status, a series of continuous data acquisition and processing operations are performed on the number of turns triggering the beat, tension waveform changes, and wire path node information during the winding process. This results in the construction of a complete cable coil counting rhythm archive. The specific implementation steps are as follows:

[0057] To address the real-time motion state during the cable coil winding process, the rotational rhythm of the winding drive end and the conductor's running beat are continuously recorded. At the beginning of the winding stage, the rotational period of the winding device and the rhythm of the conductor passing through the guide point are captured to form a time rhythm baseline for each winding action. The focus of this stage is to acquire the time beat signal representing the coil forming process, ensuring that each winding cycle corresponds to a quantifiable trigger beat unit. Simultaneously, the changes in the conductor's trajectory at different guide positions are recorded synchronously, using each change in angular displacement, translational extension, and bending node along the winding path as structural markers in the beat sequence. Through this process, a one-to-one mapping relationship is established between the time information and spatial path information of the winding process, laying the foundation for subsequent tension and path data correlation.

[0058] After establishing the beat baseline, the tension waveform generated during the cable coil winding process is continuously acquired and its changes are recorded. When the conductor is in the winding state, the force on the conductor body fluctuates periodically with different winding angles and winding densities. This tension waveform change reflects the uniformity of coil formation and the stability of the coil arrangement. In this stage, by synchronously acquiring the force change curve of the conductor during the winding process, the tension waveform characteristics within each beat cycle are paired and stored with the corresponding winding time nodes, thus forming a complete mechanical response distribution sequence in the beat data. Each tension waveform segment precisely corresponds to the corresponding number of turns triggering the beat, giving the tension information temporal correlation in the rhythm archive. In this way, the force state of the cable coil at any moment during its formation can be traced back through the beat sequence, forming a multi-dimensional synchronous recording structure, providing multi-dimensional judgment basis for subsequent identification of abnormal repetitive trajectories during the winding process.

[0059] After establishing the correspondence between beat information and tension information, the changing nodes of the conductor winding path are continuously tracked to form a spatial joint record of beat and path. By geometrically representing the movement path of the conductor on the reel during winding, the displacement changes, trajectory extension direction, and overlapping areas of the conductor at each time node are structurally recorded, so that each change in the winding path can correspond to the beat triggered by the number of turns and the tension waveform in time. During the winding cycle, every time the conductor passes through a winding turning point or completes a cross-layer movement, the system will classify the path change point into the corresponding time index in the rhythm file, thus forming a composite data sequence containing three-dimensional features of time rhythm, force fluctuation, and spatial path. The continuity of this sequence ensures that any conductor overlap, offset, or shape change during the winding process can be found in the rhythm file with the corresponding beat signal and tension change state before and after it. In this way, the rhythm file not only has continuity in the time dimension but also continuous mapping in the spatial dimension, providing a clear reference system for identifying abnormal repetitive trajectories formed by cable coils during winding.

[0060] After integrating the three types of information—beat, tension, and path—the rhythm file is logically serialized and reorganized according to the winding process, generating a counting rhythm sequence with traceable characteristics. This sequence uses the number of turns triggering the beat as the main axis, tension waveform characteristics as a dynamic correction reference, and wire path change nodes as spatial guides, forming a counting rhythm chain that can be updated in real time with the winding process. Through continuous tracking of the rhythm chain, the forming state of the coil can be located in real time during the winding process, and the differences in time and path between turns can be identified. When the coil is repeatedly wound or partially overlapped at a certain position, the corresponding beat sequence will show characteristics such as extended time intervals, smoothed tension waveforms, or overlapping paths, thus automatically forming a feature mark of abnormal repetitive trajectories in the rhythm file. Through this continuous rhythmic recording mechanism, every winding action in the entire cable coil processing process can be identified and the corresponding time, mechanical, and spatial information can be retained, ensuring the accuracy and traceability of the counting behavior.

[0061] Phase comparison of abnormal repeating trajectories is performed based on the counting rhythm sequence. When the speed change overlaps with the path, the time misalignment of the counting signal is detected, and a blank time area containing the abnormal segment is generated as a reference window for subsequent analysis.

[0062] After establishing the cable coil counting rhythm archive and generating the counting rhythm sequence, in order to identify abnormal repetitive trajectories formed during the winding process, the phase difference between each time node in the counting rhythm sequence is compared. Timing misalignment of the counting signal is detected under conditions of winding speed variation and path overlap, thereby generating a blank time region containing the abnormal segment as a reference window for subsequent analysis. The specific implementation steps are as follows:

[0063] The time information in the counting rhythm sequence is standardized, using the number of turns triggering the beat in the rhythm file as the time axis. The changes in tension waveform, path extension trajectory, and winding direction within each beat cycle are time-aligned. This method establishes a unified time baseline between the start and end times of each winding action and the beat signal. The focus of this stage is to achieve time consistency in the counting rhythm sequence, establishing an accurate correspondence between rhythm information and the actual motion state of the winding process. In this process, the tension peak and trough times within different beat cycles are also matched with the path node times, forming a rhythm time chain with temporal continuity, allowing each winding action to be accurately located in the time dimension. The continuous connection of this time chain provides a unified reference benchmark for subsequent phase comparison, ensuring comparability and consistency across time periods during the comparison process.

[0064] After establishing a unified time baseline, the time phases of consecutive winding cycles in the counting rhythm sequence are compared one by one. During the comparison, the trigger time interval between adjacent beat intervals is used as the core parameter. The trigger beat duration of adjacent turns is compared with the duration of the previous cycle to determine the extension and compression trends of the rhythm. When the speed changes during the winding process, the beat time interval will produce a phase shift. When the wire overlaps on the path, repeated winding of some paths will cause a delay in the trigger of the beat signal, resulting in time misalignment. In this stage, by comparing the time phases zone by zone, the changes in rhythm continuity during the winding process can be identified, and the specific segments of time misalignment can be determined by combining the time characteristics of the tension waveform. Through this phase difference comparison method, the time intervals in the rhythm sequence where the counting signal is misaligned can be located, providing a basis for forming blank time zones.

[0065] After identifying the time misalignment sections, a comprehensive analysis of the tension waveform and path overlap within the phase anomaly interval is conducted to confirm the duration and nature of the anomaly. By superimposing the time segments with extended intervals between consecutive peaks in the tension waveform with the spatial regions where conductors overlap or intersect in the path trajectory, the start and end points of the anomaly time period can be determined. In this process, by comparing the differences in tension fluctuation amplitude and the number of path overlaps between the anomaly segment and the preceding and following normal beat segments, the formation process and duration of the anomaly trajectory can be further clarified. When the conductor is wound multiple times on the same path, the tension fluctuations tend to be smoother, the number of path change nodes decreases, and the rhythm time interval lengthens; the time period corresponding to this state is the core range of the blank time zone. Through this joint temporal and spatial analysis, the time boundary of the anomaly superposition can be precisely defined, allowing subsequent data processing to focus only on the time windows where anomaly characteristics exist.

[0066] After identifying the abnormal time interval, the boundary of this time period is extended and the structure is summarized to form a complete blank time zone. The process of generating the blank time zone includes extending the transition beats at both ends of the time misalignment segment to cover the rhythm buffer before the anomaly and the rhythm recovery zone after the anomaly, thus ensuring that the blank time zone has a complete start and end state. Subsequently, this time interval is bound to the tension waveform characteristics, path change nodes, and loop trigger beat indexes in the rhythm file, so that the blank time zone not only contains time information but also has comprehensive mechanical and spatial data characteristics. As an independent data window, the blank time zone can provide a precise reference range for subsequent joint analysis of shape and tension, enabling continuous tracking and analysis of abnormal repetitive trajectories. In this way, the counting system can automatically identify and isolate the abnormal time period when the winding rhythm is abnormal, providing a complete data foundation for subsequent stop counting position identification and counting logic correction.

[0067] Based on the blank time zone, conduct joint analysis of shape and tension, track the slight fluctuations in the shape of the cable coil and compare the tension fluctuation characteristics to determine the stagnation position of the counting signal and output the stop counting area identifier;

[0068] After generating the blank time zone containing the abnormal segment, in order to further determine the stagnation position of the counting signal during the cable coil winding process, the coil shape change and tension fluctuation characteristics within the blank time zone are jointly analyzed. By tracking the minute fluctuations in the cable coil shape and comparing them with the dynamic characteristics of the tension curve, the stagnation position of the counting signal is finally determined and the stop counting area is identified. The specific implementation steps are as follows:

[0069] For the already generated blank time zone, the spatial morphological characteristics of the cable coil within this time zone are refined. The changes in the cable coil's shape during the winding process are recorded moment-by-moment, and the surface contour changes, interlayer superposition patterns, and coil surface undulation data are extracted using the time boundary of the blank time zone as a reference. During the winding process, the cable coil's shape exhibits slight variations depending on the conductor tension, wire density, and guide angle. These changes show regular, progressive fluctuations during normal winding, while in areas of abnormal superposition, they exhibit periodic repetition, local collapse, or uneven curvature. Therefore, in this step, the shape changes are mapped one-to-one with the time nodes of the blank time zone using a time series approach. This allows the shape change curve to reflect the local winding state within the blank time zone, providing a spatial reference for subsequent tension data matching and analysis.

[0070] Based on the shape changes, a time-corresponding synchronous analysis is performed on the tension waveform within the blank time zone, pairing the occurrence times of each peak and trough in the tension waveform with the corresponding time points of the cable coil's shape fluctuations. Under normal winding conditions, the cable coil's tension waveform exhibits stable periodic characteristics with the winding rhythm. Each tension peak typically corresponds to the peak tension of the cable conductor after completing one turn of winding, while each tension trough corresponds to the short-term relaxation state when the conductor turns. When overlapping or repeated paths occur in the winding area, the conductor repeatedly passes through the same position, causing the tension fluctuations in that area to slow down or even flatten. At this time, the time interval between adjacent peaks in the tension waveform will shift from the morphological fluctuation period in the shape change curve, thus forming a phase misalignment segment between the tension characteristics and the shape characteristics. By comparing this misalignment segment with the time boundary of the blank time zone, the time interval range in which the counting signal loses its response can be preliminarily determined.

[0071] Based on the correspondence between tension and shape, further local feature comparisons are performed on the internal details of the blank time zone to pinpoint the specific location where the counting signal stalls. This step involves jointly analyzing the amplitude changes of shape fluctuations and the intensity of tension waveform fluctuations in the blank time zone, searching for the stall point of the counting signal in sections where the synchronous changes of the two slow down or completely overlap. When the conductor is continuously wound repeatedly at a certain position, the shape curve in that area will exhibit a smooth or minimally fluctuating state, while the tension waveform will also show a continuous extension of the peak interval. The duration of this state is usually consistent with the interruption duration of the counting signal, so the stall moment of the counting signal can be confirmed by comparing the synchronously smooth intervals of shape fluctuations and tension fluctuations. In this process, the shape time points, tension time points, and counting beat signals in the blank time zone are mapped to ensure that each stall segment can be mapped onto the actual winding time axis, ensuring that the stall position of the counting signal is consistent with the physical winding position.

[0072] After determining the location of the counting signal stagnation, the temporal and spatial information of the stagnation interval is comprehensively identified to form a stagnation region identifier. This identifier includes three types of information: the start and end boundaries in the time dimension, the corresponding segment of the tension waveform, and the change segment of the shape curve. By integrating this information into the time series of the rhythm archive, the stagnation region identifier can be directly referenced in subsequent counting re-editing steps. This identifier not only records the time interval in which the counting signal stagnation occurs but also the shape and tension state of the cable coil within that interval, thus possessing multiple correlations in the time domain, morphology, and mechanics. In the subsequent counting trigger sequence reconstruction process, the stagnation region identifier can provide an accurate reference to the winding state, enabling targeted rhythm compensation and signal switching in this region during counting correction.

[0073] The counting triggering order was rearranged based on the stop counting area identifier, reverse markers were set on abnormal repeating paths and temporary bypass path detection was introduced to form a new draft counting execution order;

[0074] After generating the stop-counting area identifiers, to restore the continuity and accuracy of the cable coil processing counting process, the counting trigger sequence is rearranged for the identified stop-counting areas. This re-establishes the time correspondence between the winding action and the counting signal, ensuring that the counting logic can resume continuity in abnormal repetitive paths. The specific implementation steps are as follows:

[0075] Based on the time boundaries and spatial locations recorded by the stop counting area markers, the winding rhythms before and after the stop counting area are structured and organized. The last valid count trigger signal before the start point of the stop counting area and the first valid count trigger signal after the end point of the stop counting area are extracted and used as the basis for reconstructing the counting trigger sequence. During this process, for the winding trajectory within the stop counting area, combined with path information from the rhythm archive, the conductor running direction, winding angle changes, and path overlap status within the stop counting area are continuously recorded to determine the movement trend of the winding action under abnormal conditions. In this way, the spatial orientation of the stop counting area is kept consistent with the time boundary, providing a precise geometric reference for the subsequent setting of reverse marker points. The core of this step is to establish a continuous transition channel between the stop counting area and the valid counting area, enabling a smooth connection between the arrangement of the counting trigger sequence and the original rhythm logic.

[0076] After determining the temporal and spatial boundaries of the stop counting area, the structure of the abnormal repeating path is described in detail. The reciprocating path trajectory of the conductor in the repeating area is unfolded into a directional sequence, identifying the order in which each conductor passes through the same path segment. Based on this, reverse markers are set on the abnormal repeating path to reflect changes in the conductor's winding direction. The reverse markers are set with the center path of the stop counting area as the baseline, with markers placed at the positions where the conductor enters and leaves the repeating area, ensuring that each path reversal corresponds to a clear reverse marker. This setup introduces directional identification features into the counting trigger logic, enabling the system to distinguish between forward winding and reverse reversal of the conductor on the same spatial path. The establishment of reverse markers not only provides a basis for identifying the path direction but also allows the counting trigger signal to selectively respond according to the conductor's running direction, thereby achieving effective separation of the repeating winding state in the abnormal path area.

[0077] After the reverse marker points are set, to ensure that the reconstruction of the counting trigger sequence can cover the complete winding process in the abnormal area, a temporary bypass track detection is performed on the conductor's motion state near the stop counting area. This detection, centered on the reverse marker points, continuously tracks the conductor's trajectory along the edge of the stop counting area and its extended path, recording the conductor's spatial offset and winding angle changes. This process creates a temporary bypass track to reflect the conductor's additional motion behavior outside the abnormal path. The introduction of the temporary bypass track provides redundant path information in the abnormal area for the counting trigger sequence. When the conductor rewinds on the original path, the counting logic can perform rhythm compensation based on the trigger nodes of the bypass track, thus preventing the counting signal from stalling again in the abnormal path. This step endows the counting logic with spatial avoidance and dynamic extension characteristics, laying a dynamic foundation for the final draft of the complete counting execution sequence.

[0078] After establishing the reverse marker points and detecting temporary bypass tracks, the two types of path information are rearranged with the counting trigger beats of the original rhythm file to form a new draft counting execution sequence. This draft uses the stop-counting area identifier as the core, the reverse marker points as the boundary nodes for counting triggers, and the temporary bypass tracks as auxiliary path references, ensuring that the counting trigger signals maintain correct timing responses when the winding direction changes. In the new counting execution sequence, each trigger point in the winding process is assigned dual attributes of time and direction. When the conductor returns along an abnormal path, the trigger logic automatically adjusts the counting rhythm based on the reverse marker points and fills in the missing counting signals according to the trigger beats of the bypass tracks, thus forming a continuous and uninterrupted counting rhythm. Through this re-editing method, the draft counting execution sequence can eliminate signal misalignment caused by abnormal paths while ensuring rhythm consistency, restoring the consistent temporal and spatial correspondence of the cable coil processing counting process, and providing a structured counting rhythm foundation for subsequent rhythmic counting corrections.

[0079] The rhythmic counting correction is implemented according to the draft counting execution order. The main counting signal and the backup counting signal are triggered alternately through a two-phase counting mechanism. When winding overlap is detected, the counting path is switched to the reversal path in real time to achieve continuous and accurate results in the cable coil counting process.

[0080] After formulating a new draft counting execution sequence, to ensure the continuity and accuracy of the cable coil processing counting process under complex winding conditions, a rhythmic counting correction method is used to dynamically adjust the counting logic. An adaptive correlation is established between winding rhythm, counting signal triggering, and path switching, thereby achieving automatic switching of the counting signal between main counting and backup counting. The specific implementation steps are as follows:

[0081] Based on the existing draft counting execution sequence, the beat signals during the winding process are time-sequentially loaded, and each counting trigger point is matched to the path direction according to the time sequence in the draft. The draft counting execution sequence includes the rhythm distribution of the normal winding path, reverse marker points, and temporary bypass paths, and each piece of information has dual temporal and spatial positioning attributes. In this stage, by uniformly arranging the time rhythm of these trigger points, a valid counting trigger rhythm unit is ensured when the winding action enters any path, thus giving the entire counting process a continuous temporal rhythm. The purpose of this step is to provide a rhythmic reference for the subsequent operation of the two-phase counting mechanism, enabling the main counting signal and the backup counting signal to be triggered alternately within the same rhythmic framework, ensuring that the counting logic remains consistent in the time dimension.

[0082] After the rhythm loading is completed, the trigger logic of the two-phase counting mechanism is established, so that the main counting signal and the backup counting signal form an alternating response relationship. The main counting signal corresponds to the counting trigger event of the cable coil on the normal winding path, while the backup counting signal corresponds to the counting trigger event when the winding action occurs on the reverse path or bypass track. When the conductor runs along the original path during the winding process, the main counting signal is triggered according to the time rhythm of the rhythm file, recording the rhythm node of each winding completion; when the conductor enters an abnormal path or reverse turn-back section, the backup counting signal is triggered according to the path identifier in the draft counting execution sequence, forming a backup counting record that is continuous in time with the main counting signal. Through this two-phase alternating mechanism, the counting process can automatically complete the signal switching at the moment of path change, so that the counting rhythm is not affected by the winding direction, path overlap or short pauses, maintaining rhythm continuity. This stage realizes the continuous response of the counting signal in a multi-path environment, providing a trigger basis for the dynamic switching of winding overlap.

[0083] After the two-phase counting mechanism enters the operating state, the rhythm characteristics during the winding process are continuously monitored to identify the winding overlap state. When the conductor overlaps on the coil, the winding rhythm will periodically slow down, the interval of the beat signal will lengthen, and the trigger density of the corresponding path in the counting execution sequence draft will decrease. At this time, by dynamically tracking the rhythm time interval and the path overlap interval, it can be determined that the conductor has entered the overlap area. In this state, the main counting signal may not be able to trigger in time due to the rhythm delay, while the backup counting signal still maintains the backup triggering capability synchronized with the rhythm file. When a decrease in beat continuity or path repetition is detected, the counting logic immediately switches from the main counting signal to the backup counting signal, so that the counting process remains uninterrupted during rhythm changes. This stage, through a rhythmic trigger switching method, enables the counting logic to continuously record the winding process of the coil in the complex state of winding overlap, ensuring that every actual winding action is included in the rhythm sequence.

[0084] After achieving instantaneous switching between the main counting signal and the backup counting signal, the reversal counting path is continuously tracked to ensure the integrity of the counting signal during the reversal segment. When the conductor returns from the abnormal area to the normal path, the counting logic, based on the reverse marker point and bypass trace trigger node in the draft counting execution sequence, restores the trigger state of the main counting signal and merges the rhythm data generated by the backup counting signal during the reversal with the continuous beat of the main counting signal. In this way, the counting records of the reversal path and the counting records of the normal winding path are seamlessly connected on the timeline, forming a complete rhythmic counting chain. This chain covers all stages of the winding operation, including normal winding, overlapping reversal, and recovery path, enabling the counting data to truly reflect the entire coil forming process. Through continuous rhythm connection and signal switching, the counting results can remain stable, consistent, and accurate in complex winding environments.

[0085] This invention establishes a counting rhythm archive during cable coil processing, enabling multi-dimensional dynamic recording of turn trigger beats, tension waveforms, and changes in the winding path. This transforms the counting process from single-signal recognition to multi-source rhythm perception and timing correlation. This method continuously tracks coil shape and tension characteristics during winding. Even when abnormal overlap occurs in the winding trajectory, the integrity of the counting rhythm can be maintained based on the rhythm archive, effectively preventing processing loss of control due to interrupted counting signals. This ensures synchronization and consistency between winding progress and length control, improving the continuity and stability of the counting process.

[0086] This invention introduces a two-phase counting mechanism into the rhythmic counting correction, enabling alternating triggering of the main counting signal and the backup counting signal. This allows for immediate switching of the counting logic when the winding path repeats or reverses, ensuring accurate counting results even under complex operating conditions. This method enables adaptive switching of the counting signal under different path states, ensuring that every winding action of the cable coil is accurately counted. This significantly reduces the risk of length exceeding limits and turn errors, providing a highly reliable counting guarantee for the automatic control of cable coil processing.

[0087] The present invention provides, as shown in the figure Figure 2 The counting system shown for cable coil processing includes a rhythm file creation module, an abnormal phase analysis module, a stop counting identification module, a count re-encoding module, and a rhythmic count correction module.

[0088] The rhythm profile creation module establishes a cable coil counting rhythm profile, records the number of turns triggering beats, tension waveforms, and changes in the winding path, and generates a traceable counting rhythm sequence to identify abnormal repetitive trajectories formed during the cable coil winding process.

[0089] The abnormal phase analysis module performs phase comparison on abnormal repeating trajectories based on the counting rhythm sequence. When the speed change overlaps with the path, it detects the time misalignment of the counting signal and generates a blank time area containing the abnormal segment, which is used as a reference window for subsequent analysis.

[0090] The stop counting identification module performs joint analysis of shape and tension based on the blank time zone, tracks the slight fluctuations in the shape of the cable coil and compares the tension fluctuation characteristics to determine the position where the counting signal stops and outputs the stop counting area identifier.

[0091] The counting reprogramming module rearranges the counting trigger order according to the stop counting area identifier, sets reverse markers on abnormal repeating paths and introduces temporary bypass path detection to form a new draft counting execution order;

[0092] The rhythmic counting correction module performs rhythmic counting correction according to the draft counting execution order. It alternately triggers the main counting signal and the backup counting signal through a two-phase counting mechanism. When winding overlap is detected, it immediately switches to the reversing counting path to achieve continuous and accurate cable coil counting process.

[0093] The counting method for cable coil processing provided in this embodiment of the invention is implemented by the counting system for cable coil processing described above. For details of the specific methods and processes of the counting system for cable coil processing, please refer to the embodiments of the counting method for cable coil processing described above, which will not be repeated here.

[0094] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A counting method for cable coil processing, characterized in that, Includes the following steps: Establish a cable coil counting rhythm archive, record the number of turns triggering beats, tension waveforms, and changes in the cable routing path, and generate a traceable counting rhythm sequence; Phase comparison of abnormal repetitive paths is performed based on the counting rhythm sequence. When the speed change overlaps with the path, the time misalignment of the counting signal is detected, and a blank time zone containing the abnormal segment is generated. Specifically, this includes: standardizing the time information in the counting rhythm sequence, taking the number of revolutions triggering the beat as the time axis, and aligning the changes in tension waveform, path extension trajectory and winding direction in time sequence to form a unified time baseline; On a unified time baseline, the time phase of continuous winding cycles is compared zone by zone. By comparing the trigger time intervals of adjacent beat intervals, the time misalignment caused by changes in winding speed and path overlap is identified. After identifying the time misalignment segment, a joint analysis of the tension waveform and path overlap state is performed, and the start and end points of the abnormal time period are determined based on the extension of the peak spacing and the path overlap area. After determining the abnormal time interval, the boundary of the time interval is extended and the structure is summarized to form a blank time interval containing the abnormal segment, and then it is bound to the tension waveform characteristics, path change nodes and cycle trigger beat index. When forming the blank time zone, the transition beats at both ends of the time misalignment segment are extended so that the blank time zone simultaneously includes the rhythm buffer zone before the anomaly occurs and the rhythm recovery zone after the anomaly ends, thereby ensuring that the blank time zone has a complete start and end state and has continuous rhythm characteristics. Based on the blank time zone, conduct joint analysis of shape and tension, track the slight fluctuations in the shape of the cable coil and compare the tension fluctuation characteristics to determine the stagnation position of the counting signal and output the stop counting area identifier; The counting triggering order was rearranged based on the stop counting area identifier, reverse markers were set on abnormal repeating paths and temporary bypass path detection was introduced to form a new draft counting execution order; The rhythmic counting correction is performed in accordance with the draft counting execution order. The main counting signal and the backup counting signal are triggered alternately through a two-phase counting mechanism. When winding overlap is detected, the counting path is switched to the reversal counting path immediately.

2. The counting method for cable coil processing according to claim 1, characterized in that, The steps for establishing a counting rhythm sequence are as follows: When establishing a counting rhythm archive for cable coils, the real-time motion state of the cable coil winding process is continuously recorded first. The time rhythm baseline of the winding action is formed by acquiring the rotation rhythm of the winding drive end and the running beat of the conductor. The angular displacement change, translation extension and bending nodes of the conductor at different guide positions are recorded simultaneously. After the time rhythm baseline is established, the tension waveform during the cable coil winding process is continuously acquired. The tension waveform characteristics in each beat cycle are paired and stored with the corresponding winding time node to form a mechanical response sequence with time correlation. After establishing a correspondence between time rhythm and tension information, the changing nodes of the conductor laying path are continuously tracked, and the displacement changes, trajectory extension direction and overlapping areas are recorded as spatial joint data of beat and path. After integrating the three types of information—time, tension, and path—the rhythm file is logically serialized and reorganized according to the winding process to generate a traceable counting rhythm sequence.

3. The counting method for cable coil processing according to claim 2, characterized in that, When generating the counting rhythm sequence, the number of loops triggers the beat as the main time axis, the tension waveform characteristics are used as the force correlation information under the corresponding beat, and the cable path change nodes are used as the spatial identifiers corresponding to the beat, so that the counting rhythm sequence has time continuity, mechanical correlation and path traceability at the same time.

4. The counting method for cable coil processing according to claim 1, characterized in that, The steps for outputting the stop measurement area identifier are as follows: For the generated blank time zone, the spatial morphological characteristics of the cable coil are refined, and the shape change is matched with the time node of the blank time zone one by one to form the shape change curve. Based on the changes in shape, a synchronous analysis of the tension waveform in the blank time zone is performed to match the time points of the peaks and troughs in the tension waveform with the time points of the fluctuations in the shape of the cable coil in order to determine the time misalignment interval. Based on the correspondence between tension and shape, the internal characteristics of the blank time zone are jointly analyzed to determine the stagnation position of the counting signal in the section where the shape fluctuation and tension fluctuation change synchronously and gradually slow down. After determining the location where the counting signal stops, the time and space information of the stopping interval are comprehensively identified to form a stopping area identifier that includes time boundaries, tension waveform segments, and shape curve segments.

5. The counting method for cable coil processing according to claim 4, characterized in that, When creating the stop-counting area markers, the time boundaries are integrated with the tension waveform segments and shape curve segments according to the time sequence of the rhythm archive, so that the stop-counting area markers have multi-dimensional correlation characteristics of time, form and mechanics.

6. The counting method for cable coil processing according to claim 4, characterized in that, The steps for drafting the counting execution order are as follows: Based on the time boundary and spatial location recorded by the stop counting area identifier, the winding rhythm before and after the stop counting area is sorted out, and the effective counting trigger signals before and after the stop counting area are extracted as the basis for reconstructing the counting trigger sequence. Based on the baseline of the counting trigger sequence reconstruction, the abnormal repeat path is expanded and described, and reverse marker points are set on the abnormal repeat path to reflect the direction change of the wire during the winding process. After the reverse marker points are set, a temporary bypass track detection is performed on the conductor running trajectory near the stop measurement area to form bypass track information to supplement abnormal paths. After completing the detection of reverse markers and temporary bypass tracks, the reverse marker information, bypass track information, and counting trigger beats are rearranged to form a new draft counting execution order.

7. The counting method for cable coil processing according to claim 6, characterized in that, The rhythmic counting correction is carried out according to the draft counting execution order. A two-phase counting mechanism is used to alternately trigger the main counting signal and the backup counting signal. When winding overlap occurs, the switching to the foldback counting path is as follows: Based on the draft of the counting execution order, the counting trigger points in the winding process are loaded in a time sequence, and each counting trigger point is matched with the corresponding path direction according to the time sequence to form a continuous counting rhythm main line; After the main counting rhythm line is established, a two-phase counting mechanism is constructed so that the main counting signal corresponds to the counting trigger of the normal winding path, and the backup counting signal corresponds to the counting trigger of the reverse path and the bypass path, forming an alternating response relationship. During the operation of the biphase counting mechanism, the winding rhythm characteristics are tracked. When path repetition or rhythm interval extension occurs, the main counting signal is switched to the backup counting signal to maintain the continuity of the counting process. After the signal switching is completed, the return counting path is continuously tracked, and the rhythm data generated by the backup counting signal is merged with the beat of the main counting signal in a time sequence to form a complete rhythmic counting record.

8. A counting system for cable coil processing, used to implement the counting method for cable coil processing according to any one of claims 1-7, characterized in that, It includes a rhythm archive creation module, an abnormal phase analysis module, a stop counting identification module, a count re-encoding module, and a rhythmic count correction module: The rhythm profile creation module creates a cable coil counting rhythm profile, records the number of turns triggering beats, tension waveforms, and changes in the cable path, and generates a traceable counting rhythm sequence. The abnormal phase analysis module performs phase comparison on abnormal repeating paths based on the counting rhythm sequence. It detects time misalignment of the counting signal when the speed change overlaps with the path and generates a blank time zone containing the abnormal segment. The stop counting identification module performs joint analysis of shape and tension based on the blank time zone, tracks the slight fluctuations in the shape of the cable coil and compares the tension fluctuation characteristics to determine the position where the counting signal stops and outputs the stop counting area identifier. The counting reprogramming module rearranges the counting trigger order according to the stop counting area identifier, sets reverse markers on abnormal repeating paths and introduces temporary bypass path detection to form a new draft counting execution order; The rhythmic counting correction module performs rhythmic counting correction according to the draft counting execution order. It alternately triggers the main counting signal and the backup counting signal through a two-phase counting mechanism, and switches to the reversing counting path immediately when winding overlap is detected.

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