Device and method for metering length of wire rod of stranding machine

Abstract

The invention discloses a device and a method for metering the length of a wire rod of a stranding machine, belongs to the technical field of steel cord production equipment, and aims to solve the problem of poor metering precision of the length of the wire rod caused by transmission slip and lay length change in the conventional indirect metering mode. The metering device comprises a retro-reflection type laser sensor installed on the outer side of the equipment, a laser reflector arranged opposite to the sensor, a shading blade installed on an internal horizontal guide wheel and a PLC in signal connection with the sensor. The method comprises the steps that the shading blade intermittently shields a laser light path along with rotation of the guide wheel, the sensor generates pulse signals, and the PLC calculates the length of the wire according to the pulse number and the perimeter of the guide wheel. By directly measuring the number of turns of the guide wheel through which the formed steel cord passes, the error of a long transmission chain is eliminated, and the length measuring device is suitable for steel cord inner take-up stranding equipment and can remarkably improve the precision and reliability of length measurement.

Description

Technical Field

[0001] This invention belongs to the field of steel cord production equipment, specifically relating to a measuring device and method for measuring the length of wire from a twisting machine. Background Technology

[0002] In the twisted rope take-up equipment for steel cord production, under the original technology, because the take-up I-beam is placed inside the machine tool cradle, and there is a high-speed rotating flywheel and steel cord outside the cradle, the length of the steel cord wound on the take-up I-beam is normally measured indirectly in the following way: 1. One method involves installing a proximity switch on the outside of the flywheel spindle. The length of the steel cord wound on the take-up reel is indirectly calculated by collecting the number of rotations of the flywheel spindle. However, this method is susceptible to fluctuations in metering accuracy due to factors such as the timing belt inside the cradle, the gearbox transmission components, the untwisting device, the straightener, and slippage of the steel cord on the inner traction wheel.

[0003] 2. Another method involves installing a proximity switch on the outside of the machine tool. The length of the steel cord wound on the take-up reel is indirectly calculated by collecting the number of rotations of the external traction wheel. However, this method is less accurate because the external traction wheel only winds single filaments, and the steel cord is not fully twisted. This can be affected by variations in the twist pitch and slippage of the steel cord on the inner traction wheel, resulting in poor metering accuracy.

[0004] These defects all stem from the fact that the measurement standard is not directly related to the actual operating displacement of the stabilized steel cord. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a measuring device and method for measuring the length of wires on a twisting machine. It aims to solve the technical problems of poor accuracy and insufficient stability of existing indirect measuring methods, and to achieve high-precision and high-reliability direct length measurement with simple structure and reliable operation.

[0006] To achieve the above objectives / to solve the above technical problems, the present invention is implemented using the following technical solution: This invention provides a measuring device for the length of wire on a stranding machine, applied to an inner take-up stranding and rope-forming device. The device includes a cradle, a take-up I-beam reel and an inner traction reel disposed inside the cradle, and a horizontal guide wheel disposed on the frame of the cradle's support. The measuring device includes: A retroreflective laser sensor is fixedly installed on the outside of the cradle and is capable of emitting and receiving lasers and generating pulse signals. A laser reflector is fixedly installed on the outside of the cradle and positioned opposite to the laser sensor, thereby forming a laser signal passage path with the retroreflective laser sensor. The light-shielding blade is fixedly installed on the horizontal guide wheel and rotates synchronously with it, and is located in the laser signal passage path between the laser sensor and the laser reflector; A PLC controller is connected to the laser sensor signal and is used to receive the pulse signal generated by the laser sensor and calculate the wire length based on the number of pulse signals and the circumference of the horizontal guide wheel.

[0007] The above setup achieves the following effects: By directly setting the measurement benchmark on a horizontal guide wheel through which the twisted steel cord passes, the present invention ensures rolling contact between the guide wheel and the wire, with virtually no slippage. Using light-blocking blades fixed to the guide wheel, the rotational motion of the guide wheel is converted into periodic mechanical blocking of the stable optical path formed by the laser sensor and the reflector, thereby generating electrical pulse signals that strictly correspond one-to-one with the number of rotations of the guide wheel. The PLC controller directly calculates the wire length based on the number of these pulses and the circumference of the guide wheel. This scheme completely avoids the cumulative errors of the lengthy transmission chain (such as synchronous belts, gearboxes, etc.) from the flywheel to the take-up wheel, as well as the influence of changes in the steel cord twist pitch on measurement, thus achieving high-precision, high-reliability direct length measurement and significantly improving the accuracy of the measurement results.

[0008] Further configuration: The cross-sectional dimension of the laser beam emitted by the retroreflective laser sensor is larger than the diameter of the steel cord produced by the twisting and rope-making equipment.

[0009] The above settings achieve the following effect: This setting can effectively ensure that the multiple steel wires or stranded steel wires rotating at high speed on the flywheel cannot completely block or stably interfere with the laser beam, thereby avoiding false pulse signals that may be caused by multiple steel wires or stranded steel wires passing over the optical path, and enhancing the anti-interference capability and signal stability of the metering system under complex high-speed rotation conditions.

[0010] Further configuration: The light-shielding blades are fixed to the end of the axle of the horizontal guide wheel by welding, screwing, or integral molding.

[0011] The above setup achieves the following effect: This connection method ensures a stable mechanical connection and precise synchronous rotation between the shading blades and the horizontal guide wheel, preventing pulse signal loss or additional errors due to loose connections, and guaranteeing the reliability of the signal generation source.

[0012] Further configuration: The PLC controller has a pre-stored length conversion coefficient corresponding to the circumference of the horizontal guide wheel, and the length conversion coefficient is the effective circumference value of the horizontal guide wheel or half of the effective circumference value.

[0013] The above settings achieve the following effect: This setting directly internalizes the key geometric parameters (guide wheel circumference) into the controller, simplifying the length calculation process into a multiplication operation of pulse counting and fixed coefficients, improving processing efficiency, and facilitating rapid adaptation and calibration according to different guide wheel specifications.

[0014] Further configuration: The PLC controller is configured to multiply the number of received pulse signals by the length conversion factor to obtain the wire length measurement value.

[0015] The above settings achieve the following effect: This configuration clarifies the core calculation logic of the PLC, making the length measurement process clear and definite, and the calculation results direct and accurate, which is convenient for integration into the production management system for display, recording or use for fixed length control.

[0016] Further configuration: When the machine tool is stopped and the cradle is in a horizontal reference position, the light-shielding blade is configured such that when it rotates to block the path of the laser signal, the laser spot is located in the central region of the width and height directions of the light-shielding blade.

[0017] The above setup achieves the following effect: the installation alignment requirement provides sufficient shading margin for the normal left and right swinging of the cradle during production. Even if the cradle swings and causes the light path to shift, since the light spot is initially located at the center of the blades, it can still ensure that the shading blades within the swing range can effectively block the light path, preventing signal loss and greatly improving the robustness and adaptability of the metering device during dynamic operation of the equipment.

[0018] In a second aspect, the present invention provides a method for measuring the length of wire on a stranding machine using the measuring device described in the first aspect, comprising the following steps: S1: During the operation of the internal winding and twisting rope-making equipment, the light-blocking blades fixed on the horizontal guide wheel rotate synchronously with the horizontal guide wheel, intermittently blocking the path of the laser signal located between the laser sensor and the laser reflector. S2: The laser sensor responds to the intermittent blocking of the laser beam by generating a corresponding pulse electrical signal and sending it to the PLC controller; S3: The PLC controller calculates the length of the wire wound on the take-up reel based on the cumulative number of received pulse signals and a preset length conversion coefficient corresponding to the circumference of the horizontal guide wheel.

[0019] The above setup achieves the following effect: through a series of steps—"occlusion-induced pulse-counting calculation"—the mechanical rotation quantity in the physical world is transformed into a calculable quantity in the digital world, forming a complete and automatically executable high-precision length measurement method. This method has clear steps, is tightly integrated with the device, and realizes a reliable conversion from mechanical motion to precise digital results.

[0020] Furthermore, in step S3, the PLC controller filters the received pulse signal to remove any abnormal pulse signals.

[0021] The above settings achieve the following effect: By digitally filtering the pulse signal (such as setting a minimum time interval threshold), abnormal and high-frequency jitter signals caused by vibration, excessive cradle swing amplitude, dust, or other instantaneous interference can be effectively identified and filtered out. This ensures that each pulse entering the counting stage truly corresponds to the effective rotation of the horizontal guide wheel, further improving the purity and accuracy of the final length measurement data.

[0022] Thirdly, the present invention provides an internal winding and twisting rope-making device, including a measuring device for measuring the length of the winding machine wire as described in the first aspect.

[0023] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: Since the steel cord in front of the traction wheel inside the steel cord winding and twisting equipment has already been twisted into shape, this device and method for measuring the length of the wire in the twisting machine can prevent abnormal factors such as changes in the twist pitch, synchronous belts, gearbox transmission components, false twisters, straighteners, and slippage of the steel cord on the inner traction wheel from affecting the accuracy of steel cord length measurement during the production process. After adopting this technology, the accuracy of steel cord length measurement is improved. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall installation structure of the metering device provided by the present invention in the winding and twisting equipment.

[0025] Figure 2 yes Figure 1 A partially enlarged schematic diagram of the mounting structure of the horizontal guide wheel and the light-shielding blades; Figure 3 This is a schematic diagram of the actual installation of the metering device in the inner winding and twisting equipment.

[0026] In the diagram: 1. Wire on the pay-off side; 2. Right flywheel; 3. Left flywheel; 4. Cradle; 5. Inner traction wheel; 6. Steel cord; 7. Twisting device and straightener; 8. Horizontal guide wheel; 9. Cable laying wheel; 10. Cable laying device; 11. Take-up reel; 12. Laser sensor; 13. Connecting wire; 14. PLC controller; 15. Laser signal path; 16. Laser reflector; 17. Shading blade. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0028] In the description of this embodiment, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this embodiment and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this embodiment. Example 1

[0029] This embodiment provides a device for measuring the length of wire produced by a stranding machine. For example... Figure 1 and Figure 2 As shown, the device is installed on an inner take-up twisting and rope-forming machine. The device has a swingable cradle 4, which contains an inner traction wheel 5, a wire laying device 10, and a take-up I-beam wheel 11. Horizontal guide wheels 8 are provided on the frame of the cradle 4 support.

[0030] like Figure 1 and Figure 3 As shown, the measuring device of the present invention includes: The retroreflective laser sensor 12 is fixed to the machine tool frame outside the cradle 4 by a mounting bracket.

[0031] The laser reflector 16 is fixed to the outside of the cradle 4 and opposite to the sensor 12 by a bracket, and the two are precisely aligned to form the laser signal passage path 15.

[0032] The light-shielding blade 17, in this embodiment, is a rectangular opaque steel sheet 100mm long, 30mm wide, and 2mm thick, which is vertically fixed to the axle extension end of the horizontal guide wheel 8 by welding. During installation, ensure that the rotation plane of the light-shielding blade 17 passes through the laser signal passage path 15.

[0033] The PLC controller 14 is the original control system of the equipment, and it is connected to the pulse output terminal of the laser sensor 12 via the cable connection line 13.

[0034] Working principle: When the equipment is running, the formed steel cord 6 drives the horizontal guide wheel 8 to rotate, and the light-blocking blades 17 fixed on it rotate synchronously. Each rotation of the blades cuts into the light path 15 once, completely blocking the laser. The laser sensor 12 generates an electrical pulse signal because it cannot receive the reflected light. The pulse signal is transmitted to the PLC controller 14 via the connecting line 13.

[0035] Length Calculation: The PLC controller 14 has a pre-stored length conversion coefficient X, which is equal to the effective circumference C of the horizontal guide wheel 8 (C=πD, where D is the effective diameter of the guide wheel). The PLC accumulates and counts the received pulses N. The length L of the steel cord is calculated in real time using the formula L=XN and displayed on the human-machine interface or used for fixed-length control.

[0036] This embodiment improves the measurement accuracy from over ±0.15% of the original indirect method to within ±0.05% through the above direct measurement method, and the operation is stable and not affected by internal transmission slippage. Example 2

[0037] like Figure 1 , 2 As shown, this embodiment provides a measuring device for the length of wire from a twisting machine. In the twisting and winding equipment for steel cord production, a cradle 4 is installed between the right flywheel 2 and the left flywheel 3. Inside the cradle 4, an inner traction wheel 5, a wire-laying swing wheel 9, a wire-laying device 10, and a winding I-beam wheel 11 are installed. On the outer frame of the cradle 4, a virtual twister and straightener device 7 and a horizontal guide wheel 8 are installed.

[0038] The wire 1 on the pay-off side passes through the right flywheel 2 and the left flywheel 3 to reach the inner traction wheel 5. After being wound around the inner traction wheel 5 once, its exit end, the steel cord 6, is connected to the right end A of the virtual twister and straightener device 7 through other guide wheels. The left end B of the virtual twister and straightener device 7 is the exit end of the steel cord. The steel cord coming out from the B end of the virtual twister and straightener device 7 passes through the horizontal guide wheel 8, and then wraps around the inner traction wheel 5 several times. After passing through the wire laying wheel 9 and the wire laying device 10, it finally enters the take-up I-beam spool 11.

[0039] A retroreflective laser sensor 12 is installed on the outer sides of the right flywheel 2 and the left flywheel 3 of the inward winding and twisting rope device. A laser reflector 16 is installed on the outer side of the flywheel opposite the laser sensor 12. A light-shielding blade 17 is installed on the machine tool's horizontal guide wheel 8; the two are connected and rotate synchronously. This ensures that the laser signal travels along the same path as the path 15, the laser reflector 16, and the light-shielding blade 17.

[0040] like Figure 2 As shown, during the production process, as the horizontal guide wheel 8 inside the machine tool rotates, the light-blocking blades 17 mounted on it intermittently block the laser signal from passing through path 15, thereby causing the laser sensor 12 to emit intermittent electrical pulse signals. The laser sensor 12 is connected to the PLC controller 14 of the twisting equipment via connecting cable 13.

[0041] In the PLC controller 14, a steel cord metering coefficient X (length conversion coefficient) is set according to the circumference of the horizontal guide wheel 8. The PLC controller 14 receives the number N of electrical pulse signals emitted by the laser sensor 12 to measure the length of the steel cord wound on the internal take-up I-beam 11, that is, X*N=steel cord length in meters.

[0042] Preferably, the size of the laser beam emitted by the laser sensor 12 is larger than the diameter of the wire produced by the twisting and rope-making equipment, so as to ensure that the laser emission and return signals are not interfered with during the high-speed rotation of the steel wires on the left and right flywheels. Alternatively, other infrared sensors can be used instead of the laser sensor.

[0043] Preferably, the light-shielding blade 17 needs to be set with a certain height and width; the cradle 4 should be kept as horizontal as possible when the machine tool is stopped; the laser point position after the laser beam emitted by the laser sensor 12 is blocked by the light-shielding blade 17 should be kept as central as possible in the light-shielding blade 17, so as to minimize the risk of the laser signal deviating from the range of the light-shielding blade 17 through the path 15 due to the left and right swing of the cradle 4 during the production operation of the machine tool.

[0044] Specifically, such as Figure 2 As shown, the overall system of this embodiment includes the following components: The wire 1 on the pay-off side is a long, thin, cylindrical metal wire or stranded wire. It is drawn from the external pay-off device and first enters and passes through the right-side flywheel 2. It is used as raw material for the production of steel cord 6, providing single or multiple wires for the wet drawing process.

[0045] The right flywheel 2 is a high-speed rotating disc or wheel structure. It is mounted on the machine tool via a spindle and arranged in pair with the left flywheel 3. The wire 1 on the pay-off side is introduced through it and fed into the cradle 4 together with the wire from the left. It serves as part of the twisting mechanism, driving the wire to rotate at high speed, causing it to twist, and initially twisting it with the wire from the left.

[0046] The left flywheel 3 is a high-speed rotating disc or wheel symmetrical in structure to the right flywheel 2. It is mounted on the machine tool via a spindle and arranged in pair with the right flywheel 2 to feed the steel wire into the cradle 4. Its function is the same as the right flywheel 2, providing steel wire from the other side and participating in twisting to form the preparatory structure before stranding.

[0047] Cradle 4 is a frame structure that can swing left and right. It is mounted on the machine tool body via bearings or a suspension mechanism. Its interior houses the inner traction wheel 5, the wire-laying swing wheel 9, the wire-laying device 10, and the take-up I-beam spool 11. A twister and straightener device 7 and a horizontal guide wheel 8 are mounted on its frame. It serves as the core load-bearing frame for the inner take-up section, swinging during equipment operation to ensure that the steel cord 6 is evenly wound onto the take-up I-beam spool 11.

[0048] The inner traction pulley 5, a cylindrical guide wheel, typically has grooves on its surface to prevent wire slippage. It is installed inside the cradle 4. Steel wire / cord from the flywheel is first wound onto it, then led out to the twister and straightener device 7, and then returned and wound onto it again. It provides traction friction, pulling the steel cord 6 within the cradle 4 system, and is one of the main points of application of wire tension.

[0049] The steel cord 6 is a spiral composite cable made of multiple steel wires twisted together. It travels within the system, sequentially connecting to the strands formed by the twisting of the wires 1 on the pay-off side, the inner traction wheel 5, the twister and straightener device 7, the horizontal guide wheel 8, and the winding wheel 9, finally winding onto the take-up reel 11. It is the final product processed by this device, and its length is the object to be measured in this invention.

[0050] The virtual twister and straightener device 7 is typically a combined unit with a rectangular or cylindrical outer shell. Internally, it contains a rotating component that creates a virtual twist in the steel wire, as well as a set of straightening wheels. It is fixedly mounted on the outer frame of the cradle 4 and connected in series between the outlet end of the inner traction wheel 5 and the inlet end of the horizontal guide wheel 8. It is used to perform a final twist (virtual twist) on the stranded steel wire to transform it into a true steel cord 6, and to eliminate stress and straighten the wire using the straightening wheels.

[0051] A horizontal guide wheel 8, cylindrical in shape, is horizontally mounted and fixedly installed on the outer frame of the cradle 4. Steel cord 6 passes over its surface. A light-shielding blade 17 is fixedly mounted at the end of its axle. This blade guides the steel cord 6 to change its direction. Its core function is to serve as a reference measuring wheel for length measurement in this invention. Its rotation circumference is proportional to the length of the steel cord 6 it passes over, and because it directly contacts the formed steel cord 6, the slippage rate is low, ensuring a reliable measurement reference.

[0052] The cable guide wheel 9 is a small cylindrical guide wheel. It swings up and down with the guide wheel on the cable guide device 10. The steel cord 6 passes through its groove. It serves as a guide wheel before the steel cord 6 enters the cable guide device 10 at the outlet end of the inner traction wheel 5.

[0053] The cable laying device 10 is a linear reciprocating motion mechanism composed of a lead screw, guide rail, and sliding seat. It is fixedly installed inside the cradle 4. It enables the steel cord 6 to be neatly laid on the I-beam reel.

[0054] The take-up reel 11 is a cylindrical drum (I-beam reel) with flanges on both sides. It is mounted inside the cradle 4 via a shaft and bearings and is driven to rotate by mechanical transmission. The steel cord 6 is finally wound onto its drum. It is used to wind the pre-processed finished steel cord 6 and is the end point of the production process.

[0055] The laser sensor 12, a retroreflective type, typically has a cuboid housing and integrates a laser emitter and receiver. It is fixedly mounted on the machine tool frame outside the cradle 4 via a bracket. The emitted laser beam travels along laser signal path 15 to the laser reflector 16. It is electrically connected to the PLC controller 14 via connecting cable 13. It is used to emit laser light and detect whether it is reflected back. When the light path is blocked by the light-blocking leaf 17, it outputs a state change signal, which is the core detection element for generating the length measurement pulse signal.

[0056] Connection line 13, a cable or wire. Its two ends are connected to the signal output terminal of the laser sensor 12 and the input port of the PLC controller 14, respectively. It is used to transmit the electrical pulse signal generated by the laser sensor to the PLC controller 14.

[0057] PLC controller 14, an industrial programmable logic controller, is typically a cabinet or modular structure. It is installed inside the electrical control cabinet. It receives signals from the laser sensor via connection cable 13. It is used to receive and process pulse signals, calculate and output the length value of the steel cord 6 based on the preset circumference parameters of the horizontal guide wheel 8, and serves as the processing and output center for metering data.

[0058] The laser reflector 16, a planar reflective mirror, typically comes with a mounting bracket. It is fixedly mounted on the outside of the cradle 4 via the bracket, positioned opposite the laser sensor, precisely at the end of the laser signal path 15. It is used to reflect the laser beam emitted by the laser sensor back along its original path, forming a retroreflective detection optical path together with the sensor, simplifying alignment and improving reliability.

[0059] The light-shielding blade 17 is a rectangular or fan-shaped sheet of metal. It is vertically fixed to the end of the axle of the horizontal guide wheel 8 and rotates synchronously with the horizontal guide wheel 8. Its installation position ensures that it can cut into and completely block the laser signal from passing through path 15 during the rotation cycle. It is used to convert the mechanical rotational motion of the horizontal guide wheel 8 into periodic blocking of the laser signal passing through path 15, thereby triggering the laser sensor to generate an electrical pulse signal corresponding to the number of rotations of the guide wheel. It is a "trigger" for converting mechanical quantity into electrical signal.

[0060] This invention provides a direct measurement scheme based on non-contact photoelectric sensing. The core of its structural principle lies in converting the linear displacement of the formed steel cord 6 into countable electrical pulse signals through a high-precision mechanical-photoelectric conversion link, and then converting it into a length value by the control system.

[0061] System composition and layout principles: Selection of reference measurement point: Instead of relying on the flywheel spindle or external traction wheel for traditional indirect measurement, a horizontal guide wheel 8 located on the stable running path of the steel cord 6 after it has been twisted and before it enters winding is selected as the measurement reference. This guide wheel has rolling contact with the steel cord 6, the transmission chain is extremely short (only the guide wheel itself), and there is almost no slippage, which fundamentally eliminates the influence of accumulated errors from long transmission chains and changes in twist pitch.

[0062] The sensing system is constructed as follows: A stable photoelectric detection loop is built outside the cradle 4. The laser sensor and the laser reflector 16 are fixedly installed relative to each other, forming a laser signal path 15 that spans the external space of the cradle 4. This layout physically isolates the detection system from the high-speed rotating and vibrating components inside the equipment, improving system stability and anti-interference capability.

[0063] Integration of the mechanical-to-photoelectric converter: A light-shielding blade 17 is fixedly mounted on the rotating shaft of the horizontal guide wheel 8, which serves as the metrological reference. This blade acts as a "pointer" or "code disk," converting the rotational motion of the guide wheel into periodic mechanical blocking of the fixed optical path.

[0064] Signal generation and processing principles: Pulse signal generation: When the equipment is running, the steel cord 6 drives the horizontal guide wheel 8 to rotate, and the light-blocking blades 17 rotate synchronously. Each rotation cuts into the optical path twice, completely blocking the laser beam, causing the laser sensor to receive no reflected light, thus outputting a complete electrical pulse (e.g., changing from a high level to a low level and then back to normal). Each rotation of the horizontal guide wheel 8 generates two electrical pulses.

[0065] Length conversion principle: A key parameter is preset in the PLC controller 14—the length conversion coefficient X, which is equal to the effective circumference (C) of the horizontal guide wheel 8. The controller accumulates and counts the received pulse signals (denoted as N). Based on the basic principle that displacement = number of turns × circumference, the cumulative passing length (L) of the steel cord 6 can be accurately calculated using the formula L = XN.

[0066] Anti-interference and reliability design principles: Optical path stability design: The retroreflective laser sensor 12 is adopted, which integrates the transmitter and receiver. Only a reflector needs to be installed on the opposite side, simplifying the alignment requirements and making the optical path more stable and reliable.

[0067] Anti-false triggering design: By setting the cross-sectional size of the laser beam to be larger than the diameter of multiple steel wires or stranded steel wires, it is ensured that the multiple steel wires or stranded steel wires rotating at high speed on the flywheel will not completely block or seriously interfere with the laser beam, thus avoiding the generation of false pulses.

[0068] Swing compensation design: By rationally designing the width and height of the light-shielding blade 17 and ensuring that the laser spot is located in the center of the blade when the cradle 4 is in a horizontal reference position during installation, a shielding margin is reserved for the normal left and right swing of the cradle 4 during operation, preventing signal loss due to swing. Example 3

[0069] This embodiment provides a method for measuring the length of wire using a twisting machine employing the measuring device described in Embodiment 2, including the following steps: S1: During the operation of the internal winding and twisting rope-making equipment, the light-blocking blade 17 fixed on the horizontal guide wheel 8 rotates synchronously with the horizontal guide wheel 8, intermittently blocking the laser signal passing through path 15 between the laser sensor and the laser reflector 16; S2: The laser sensor responds to the intermittent blocking of the laser beam by generating a corresponding pulse electrical signal and sending it to the PLC controller 14; S3: The PLC controller 14 calculates the length of the wire wound on the take-up reel 11 based on the cumulative number of received pulse signals and the preset length conversion coefficient corresponding to the circumference of the horizontal guide wheel 8.

[0070] By employing a series of steps—"occlusion-induced pulse-counting calculation"—the mechanical rotation quantities of the physical world are transformed into calculable quantities in the digital world, forming a complete and automated high-precision length measurement method. This method features clear steps, is tightly integrated with the device, and achieves a reliable conversion from mechanical motion to precise digital results.

[0071] In step S3, the PLC controller 14 filters the received pulse signal to remove abnormal pulse signals caused by vibration, excessive cradle swing amplitude, dust, etc.

[0072] By digitally filtering the pulse signal (such as setting a minimum time interval threshold), abnormal and high-frequency jitter signals caused by mechanical vibration of the equipment or other instantaneous interference can be effectively identified and filtered out, thereby ensuring that each pulse entering the counting stage truly corresponds to the effective rotation of the horizontal guide wheel 8, further improving the purity and accuracy of the final length measurement data.

[0073] The operation method of this invention is clear and standardized, and can be divided into two main stages: installation and commissioning, and operation and measurement.

[0074] Phase 1: Installation and Debugging 1. Install the light-shielding blade 17: Securely install the light-shielding blade 17 (e.g., by welding or screwing) onto the axle extension end of the horizontal guide wheel 8. Ensure that the blade plane is perpendicular to the guide wheel axis and that the installation is secure and without looseness.

[0075] 2. Install the laser sensor and reflector: Select a safe and stable location on the machine tool frame outside the cradle 4 and install the laser sensor.

[0076] On the outer frame of the cradle 4 directly opposite the sensor, install the laser reflector 16 to ensure that the two are roughly aligned.

[0077] Initially connect the laser sensor power supply, fine-tune the angle and position of the sensor and reflector until the sensor indicator (such as a green light) indicates that a stable optical path has been established, that is, the laser signal has been established through path 15.

[0078] 3. Alignment and calibration: Stop the twisting machine and manually adjust cradle 4 to the horizontal reference position (i.e., the middle position during production).

[0079] Manually rotate the shading blade 17 to a position that completely blocks the laser beam path.

[0080] Observe the laser sensor indicator (turning red or signal disconnection). In this state, check the actual landing point of the laser spot on the shading blade 17. By fine-tuning the sensor / reflector mounting bracket, or fine-tuning the mounting angle of the shading blade 17 (if adjustable), strive to ensure that the laser spot falls in the center area of ​​the width and height of the shading blade 17. This step is crucial to ensuring that the cradle 4 does not lose signal when it swings.

[0081] 4. Electrical Connections and Parameter Settings: Use cable 13 to connect the signal output terminal of the laser sensor to the designated high-speed counting input port of the PLC controller 14.

[0082] In the PLC control program, a length conversion factor X is set. This factor needs to be calculated based on the effective diameter (D) of the horizontal guide wheel 8 (including its groove) as measured in reality: if it is a single-sided baffle of the shaft (blocking only once per revolution), then X=πD; if it is a double-sided baffle of the shaft (blocking twice per revolution), then X=πD / 2.

[0083] Preferably, filtering parameters are set in the PLC program, such as setting the minimum pulse interval time, to filter out abnormal jitter signals that may be caused by vibration, excessive cradle swing amplitude, dust, etc.

[0084] Phase Two: Operation and Measurement 1. Start the equipment: Start the twisted rope winding equipment according to the normal procedure. The steel cord 6 starts running and drives the horizontal guide wheel 8 to rotate.

[0085] 2. Automatic signal generation: As the horizontal guide wheel 8 rotates, the light-blocking blades 17 periodically block and open the laser signal through path 15. The laser sensor converts this light on / off state into electrical pulse signals in real time.

[0086] 3. Signal transmission and processing: The pulse signal is transmitted to the PLC controller 14 in real time through the connection line 13. The PLC's internal counter accumulates the pulses.

[0087] 4. Length Calculation and Output: The PLC calculates the length L (L=XN) of the steel cord 6 in real time based on the preset conversion factor X and the cumulative pulse count N. The calculation result can be used for: The current meter length, shift output, etc. are displayed in real time on the human-machine interface (HMI).

[0088] Achieve automatic stopping control at fixed length: When the length reaches the preset value, the PLC issues a stop command.

[0089] The length data is uploaded to the Manufacturing Execution System (MES) for quality traceability and data analysis.

[0090] 5. Monitoring and Maintenance: Operators can monitor the stability of the pulse signal through the HMI. If an abnormal counting occurs (such as no pulse for a long time or pulses too fast), the system can alarm and prompt to check whether the optical path is accidentally blocked, whether the sensor is faulty, or whether the light-shielding blade 17 is loose.

[0091] The structural principle of this invention is to construct a direct, stable, and high-precision wire length measurement system through an innovative hardware combination of a "reference guide wheel + photoelectric shielding + pulse counting". Its operation method is highly standardized, and it can operate fully automatically after installation and debugging. It transforms the complex length measurement problem into a reliable pulse counting problem, significantly improving the measurement accuracy and intelligence level of steel cord production. Example 4

[0092] This embodiment provides an internal winding and twisting rope-making device, including a measuring device for the length of the winding machine wire as described in Embodiment 1.

[0093] By directly integrating high-precision measurement functions into the production equipment, the equipment not only completes the basic process of twisting and rope making, but also has its own reliable wire length measurement capability, which improves the intelligence level and overall value of the equipment.

[0094] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature, and in the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0095] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0096] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0097] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0098] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. A measuring device for the length of wire on a twisting machine, applied to an inner take-up twisting and rope-forming device, the device comprising a cradle, a take-up I-beam reel and an inner traction reel disposed inside the cradle, and a horizontal guide wheel disposed on the frame of a support of the cradle, characterized in that, The device includes: A retroreflective laser sensor is fixedly installed on the outside of the cradle and is capable of emitting and receiving lasers and generating pulse signals. A laser reflector is fixedly installed on the outside of the cradle and positioned opposite to the laser sensor, thereby forming a laser signal passage path with the retroreflective laser sensor. The light-shielding blade is fixedly installed on the horizontal guide wheel and rotates synchronously with it, and is located in the laser signal passage path between the retroreflective laser sensor and the laser reflector; A PLC controller is connected to the laser sensor signal and is used to receive the pulse signal generated by the retroreflective laser sensor and calculate the wire length based on the number of pulse signals and the circumference of the horizontal guide wheel.

2. The device for measuring the length of wire on a twisting machine according to claim 1, characterized in that, The cross-sectional dimension of the laser beam emitted by the retroreflective laser sensor is larger than the diameter of the steel cord produced by the twisting and rope-making equipment.

3. The device for measuring the length of wire on a twisting machine according to claim 1, characterized in that, The light-shielding blades are fixed to the end of the axle of the horizontal guide wheel by welding, screwing, or integral molding.

4. The device for measuring the length of wire on a twisting machine according to claim 1, characterized in that, The PLC controller has a pre-stored length conversion coefficient corresponding to the circumference of the horizontal guide wheel.

5. The measuring device for measuring the length of wire on a twisting machine according to claim 4, characterized in that, The PLC controller is configured to multiply the number of received pulse signals by the length conversion factor to obtain the wire length measurement value.

6. The device for measuring the length of wire on a twisting machine according to claim 1, characterized in that, When the machine tool is stopped and the cradle is in a horizontal reference position, the light-shielding blade is configured such that when it rotates to block the path of the laser signal, the laser spot is located in the central region of the width and height directions of the light-shielding blade.

7. A method for measuring the length of wire on a stranding machine using the measuring device described in any one of claims 1-6, characterized in that, Includes the following steps: S1: During the operation of the internal winding and twisting rope-making equipment, the light-blocking blades fixed on the horizontal guide wheel rotate synchronously with the horizontal guide wheel, intermittently blocking the path of the laser signal located between the laser sensor and the laser reflector. S2: The retroreflective laser sensor responds to the intermittent blocking of the laser beam by generating a corresponding pulse electrical signal and sending it to the PLC controller; S3: The PLC controller calculates the length of the wire wound on the take-up reel based on the cumulative number of received pulse signals and the preset length conversion coefficient corresponding to the circumference of the horizontal guide wheel.

8. The measurement method according to claim 7, characterized in that, In step S3, the PLC controller filters the received pulse signal to remove any abnormal pulse signals.

9. A winding and twisting rope-making device, characterized in that, Includes a measuring device for measuring the length of wire from a twisting machine as described in any one of claims 1-6.

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