Electric control system and method of full-automatic disc-changing winding displacement machine
The fully automatic reel-changing and take-up cable machine's electrical control system solves the production interruption problem caused by manual reel changing, achieving automated reel changing and production continuity, thus improving production efficiency and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- DALIAN KONFORM TECH CO LTD
- Filing Date
- 2026-03-16
- Publication Date
- 2026-04-21
AI Technical Summary
The existing take-up and wire-laying machine requires manual intervention during the reel changing process, which leads to production interruption and seriously affects production efficiency.
An electronic control system for a fully automatic reel-changing cable take-up and lay-out machine was designed, including a core control module, a drive module, a detection and feedback module, a reel-changing control module, and a human-machine interaction module. Through collaborative work, the system achieves seamless connection between the take-up and lay-out actions and the reel-changing process. It adopts a take-up and lay-out synchronous control algorithm, a tension adjustment algorithm, and a reel-changing timing coordination algorithm to ensure stable cable tension and synchronous take-up and lay-out.
It achieves automatic reel changing without human intervention, reducing the reel changing time to less than 30 seconds, ensuring production continuity, improving production efficiency, and maintaining the consistency of cable product quality.
Smart Images
Figure CN121894492A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of intelligent electrical control technology for cable processing equipment, and in particular to an electrical control system and method for a fully automatic reel-changing and take-up cable machine. Background Technology
[0002] In the continuous and large-scale production of wires and cables, the take-up and unwinding machine is a key piece of equipment used to neatly and tightly wind finished or semi-finished cables onto reels. Currently, after a single reel is full, manual intervention is typically required to perform a series of operations, including slowing down / stopping the machine, cutting the cable, replacing the empty reel, securing the cable end, and restarting the equipment. The main technical problem with this manual reel-changing method is that production is forced to stop during the reel-changing process, causing the production line to be unable to operate continuously and severely restricting production efficiency. Summary of the Invention
[0003] The purpose of this application is to provide an electrical control system and method for a fully automatic reel-changing and take-up cable machine, which can solve the technical problems of production interruption and low efficiency caused by manual reel changing in the prior art.
[0004] To achieve the above objectives, this application provides the following solution: In a first aspect, this application provides an electrical control system for a fully automatic reel-changing and take-up cable machine, the electrical control system of which includes: The core control module is used to coordinate the cable take-up and cable run-up actions and the reel changing process. It has built-in cable take-up and cable run-up synchronization control algorithm, tension adjustment algorithm and reel changing timing coordination algorithm. The drive module is communicatively connected to the core control module. The drive module includes a take-up and lay-up drive unit for driving the take-up and lay-up operation, and an actuator driver for performing the reel-changing action. The detection feedback module is electrically connected to the core control module. The detection feedback module includes a cable take-up and cable run-up parameter detection unit for collecting cable take-up and cable run-up parameters, and a reel change status detection unit for collecting status signals during the reel change process. The disk changing control module is electrically connected to the core control module. The disk changing control module is used to receive instructions from the core control module and drive the actuator to complete the disk changing action according to the instructions. The human-machine interaction module is communicatively connected to the core control module. The human-machine interaction module is used to realize parameter setting, status display and fault alarm.
[0005] Optionally, the core control module adopts a programmable logic controller with a process fieldbus and a high-speed input / output interface. The core control module communicates bidirectionally with the drive module, the detection feedback module, the disk changing control module and the human-machine interaction module through the process fieldbus.
[0006] Optionally, the take-up cable drive unit includes: Take-up motor driver, used to drive the take-up reel to rotate; Cable driver, used to drive the cable reciprocating motion; Tension adjustment driver, used to adjust and maintain cable tension during take-up and reel changing; Product-oriented drive, used to switch the position of the cable between the main take-up reel and the spare reel; A traction drive is used to drive the traction device to achieve speed synchronization with the host machine.
[0007] Optionally, the drive module further includes: Tape applicator driver, used to drive the tape applicator mechanism to complete the tape applicator operation; Automated guided vehicles are used to automate the transfer of full and empty pallets. A reel lifting drive is used to drive the loading and unloading of the reel.
[0008] Optionally, the take-up and cabling parameter detection unit includes: Cable position sensor is used to detect the real-time position of the cable connector; A speed sensor is used to detect the real-time speed of the take-up reel; The disk changing status detection unit includes: The cable reel fullness detection sensor is used to detect whether the cable reel is full. The spool positioning sensor is used to detect whether an empty spool has been installed in a preset position.
[0009] Optionally, the full-reel detection sensor is a diffuse reflection photoelectric sensor, installed above the take-up reel; the reel positioning sensor is a proximity switch, installed on the reel mounting base.
[0010] Optionally, the disk changing control module includes: The disk swapping logic processing unit is used to store and execute preset disk swapping modes and disk swapping timing processes; An actuator control unit is used to drive the actuator driver to operate according to the instructions of the core control module; The disk changing status feedback unit is used to feed back the status signals of each stage during the disk changing process to the core control module in real time.
[0011] Optionally, the reel-changing mode includes an automatic reel-changing mode that is automatically triggered based on a full reel signal, and a manual reel-changing mode that is triggered by instructions from the human-machine interaction module.
[0012] Secondly, this application provides an electronic control method for a fully automatic reel-changing take-up and cable laying machine, applied to the electronic control system of the fully automatic reel-changing take-up and cable laying machine described in any one of the first aspects, wherein the electronic control method for the fully automatic reel-changing take-up and cable laying machine includes: The parameters for cable reeling and reel changing can be set via the human-computer interaction module. The core control module controls the drive module to perform cable winding and laying operations based on the real-time signals collected by the detection feedback module, and the tension adjustment algorithm maintains stable cable tension. When the status signal collected by the detection feedback module meets the preset disk replacement triggering conditions, the core control module triggers the disk replacement process. The core control module coordinates and controls the drive module and the reel-changing control module to sequentially complete the actions of main take-up reel deceleration, cable guidance switching, cable cutting, and cable fixing to the spare reel according to the preset reel-changing sequence. The core control module switches the backup reel that has been wired to the main take-up reel, resumes the take-up and wire laying operation, and controls the automatic guided transport vehicle and the reel lifting drive to complete the transfer of full reels and the loading of empty reels.
[0013] Optionally, the reel-changing triggering conditions include: the reel full-reel detection sensor detecting that the diameter of the main take-up reel has reached a preset full-reel diameter threshold, or receiving a manual reel-changing command issued through the human-machine interaction module.
[0014] According to the specific embodiments provided in this application, the following technical effects are disclosed: This application provides an electrical control system and method for a fully automatic reel-changing take-up and lay-up cable machine. By setting a core control module as the system control center, this module incorporates a take-up and lay-up synchronization control algorithm, a tension adjustment algorithm, and a reel-changing timing coordination algorithm to coordinate the take-up and lay-up actions with the reel-changing process. This enables the system to manage normal production and reel-changing operations in a unified manner, ensuring seamless integration of the two processes and providing a decision-making and control basis for subsequent automated reel-changing. It effectively solves the problem of process interruption caused by improper manual coordination. A drive module is also included, comprising a take-up and lay-up drive unit for driving the take-up and lay-up operations and an actuator driver for executing the reel-changing actions. The take-up and lay-up drive unit is responsible for continuous actions such as take-up, lay-up, and tension adjustment in daily production, ensuring efficient and stable normal production. The actuator driver is specifically designed for high-speed, precise actions during reel changing (such as cable cutting and fixing), ensuring rapid response and reliable execution of the reel-changing actions. The two have clearly defined roles and work together, avoiding the contradiction that a single drive system cannot handle both continuous operation and instantaneous actions. By setting up a detection feedback module, which includes a take-up / layout parameter detection unit for collecting take-up / layout operation parameters and a reel-changing status detection unit for collecting status signals during reel changing, the system achieves a fully automated closed-loop control of the reel-changing process. The take-up / layout parameter detection unit monitors key parameters such as layout position and rotation speed in real time, providing precise feedback for synchronous control and tension adjustment. The reel-changing status detection unit detects whether the reel is full or empty, providing reliable criteria for reel-changing triggering and process control. This enables the system to accurately perceive equipment status and ensure precise execution of control commands. A reel-changing control module receives commands from the core control module and drives the actuator to complete the reel-changing action. As the command execution layer, the reel-changing control module translates the logical commands of the core control module into physical actions and ensures the accurate completion of each step through an internal status feedback mechanism, achieving fully automated closed-loop control of the reel-changing process and completely eliminating the need for manual intervention. A human-machine interaction module enables parameter setting, status display, and fault alarms. Operators can easily set cable routing parameters and reel change thresholds through this module, monitor equipment operating status and reel change progress in real time, and promptly obtain alarm information when a fault occurs. This ensures both the ease of system operation and improves the efficiency and safety of equipment maintenance.
[0015] This application constructs a closed-loop control system through the organic integration and collaborative operation of the aforementioned five modules. This system can automatically complete full-reel detection, reel switching, cable cutting, and securing. The system can automatically complete reel changes without manual intervention, reducing the reel change time to less than 30 seconds. This fundamentally solves the technical problems of production interruption and low efficiency caused by manual reel changes, as pointed out in the background art, and significantly improves the continuous operation capability of the production line. Simultaneously, through the coordinated control of multiple algorithms built into the core control module, seamless connection between the cable winding and reel changing actions is ensured, maintaining stable cable tension and synchronous accuracy of winding and winding, thus guaranteeing the consistency of cable product quality. Attached Figure Description
[0016] 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 of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0017] Figure 1 A schematic diagram of the functional modules of the electrical control system of a fully automatic reel-changing take-up and cable-laying machine provided in an embodiment of this application; Figure 2 This is a schematic diagram of the overall mechanism of the cable take-up and cable laying machine provided in an embodiment of this application; Figure 3 This is a schematic diagram illustrating the take-up state of the right take-up device according to an embodiment of this application; Figure 4 This is a schematic diagram of the right take-up device in a fully taken-up state according to an embodiment of this application; Figure 5 This is a schematic diagram of a replacement device for the left take-up arm provided in an embodiment of this application; Figure 6 This is a flowchart illustrating the electrical control method of a fully automatic reel-changing take-up and cable-laying machine according to an embodiment of this application.
[0018] In the picture: 1. Cable, 2. Left cable reel-in device, 3. Guide device, 4. Right cable reel-in device, 5. Cable storage device, 6. Left tape applicator, 7. Right tape applicator, 8. Track traction device. Detailed Implementation
[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0020] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.
[0021] In one exemplary embodiment, such as Figure 1 As shown, an electronic control system for a fully automatic reel-changing cable take-up and unwinding machine is provided. This system includes a core control module 101, a drive module 102, a detection and feedback module 103, a reel-changing control module 104, and a human-machine interface module 105. These modules are coupled together via a process fieldbus (e.g., Profinet) and / or electrical connections to form a collaborative closed-loop control system.
[0022] The core control module 101 serves as the system control center, coordinating the cable take-up and cable run-up actions and the reel changing process. It incorporates a cable take-up and cable run-up synchronization control algorithm, a tension adjustment algorithm, and a reel changing timing coordination algorithm.
[0023] As an optional implementation, the core control module 101 employs a programmable logic controller (PLC) with a process fieldbus and high-speed input / output interfaces. Specifically, a Siemens S7-1200 series PLC can be used, which features a Profinet interface and high-speed input / output ports, meeting the requirements for real-time control and large-volume data communication. The take-up and cable-layout synchronization control algorithm calculates the matching relationship between the take-up reel's rotation speed and the cable layup device's displacement, ensuring the cable is evenly arranged on the take-up reel and preventing overlap or excessive gaps. The tension adjustment algorithm uses a PID control strategy, dynamically adjusting the tension adjustment driver based on the tension value collected in real-time by the detection feedback module 103, ensuring the cable maintains constant tension during take-up and reel changes. The reel-changing timing coordination algorithm defines a complete reel-changing state machine, including multiple states such as full reel detection, take-up deceleration, cable guidance switching, cable cutting, cable fixing, and take-up acceleration recovery, coordinating the actions of each module in a predetermined sequence after the reel change is triggered.
[0024] This implementation method endows the core control module 101 with powerful data processing and real-time control capabilities, providing a hardware foundation for the operation of complex algorithms and high-speed communication. Through its three built-in core algorithms, the core control module 101 can accurately calculate the synchronization relationship between take-up and take-up cables, dynamically maintain tension stability, and orderly schedule the reel-changing process, ensuring the efficient and coordinated operation of the entire system.
[0025] In this embodiment, the take-up and cable delivery synchronization control algorithm ensures precise matching between the take-up reel's rotational speed and the cable delivery device's displacement, preventing cable overlap or excessive gaps on the take-up reel. The algorithm's implementation principle is as follows: The core control module 101 collects the pulse signal from the take-up reel's rotational speed sensor (incremental encoder) in real time, calculates the real-time rotational speed n (revolutions / minute) of the take-up reel, and then calculates the linear speed v = π × D × n / 60, where D is the current diameter of the take-up reel (estimated based on a full-reel detection sensor or the cumulative number of revolutions). Simultaneously, the core control module 101 calculates the theoretical moving speed v required by the cable delivery device based on the set cable delivery pitch P (mm / revolution). p = v × P / (π × D). The cable position sensor (absolute encoder) provides real-time feedback on the actual position of the cable arranger. The core control module 101 compares the actual position with the theoretical position and uses a PID controller to perform closed-loop adjustment of the cable motor driver to ensure that the actual moving speed of the cable arranger is consistent with the theoretical speed, thereby achieving precise synchronization between cable take-up and cable laying.
[0026] This implementation method enables the take-up and cable routing synchronization control algorithm to calculate the required speed of the cable routing device in real time based on the take-up reel speed and the set pitch, and ensures precise matching between the two through closed-loop control, thereby guaranteeing the uniformity and neatness of the cable arrangement.
[0027] In this embodiment, the tension adjustment algorithm is used to maintain constant cable tension during cable winding and reel changing. The tension adjustment algorithm employs a PID control strategy, and its implementation principle is as follows: A tension sensor (such as a dance wheel position sensor or a direct tension sensor) is installed on the cable storage device to collect the actual cable tension value T in real time. actual The core control module 101 will T actual The target tension value T set through the human-computer interaction module 105 target Compare and calculate the deviation e = T target - T actual The core control module 101's built-in PID controller performs proportional, integral, and derivative calculations based on the deviation e, outputting a control quantity U = K. p × e + K i × ∫e dt + K d × d e / dt K p K i K dThe preset PID parameters are used. The output control quantity U is sent as a command to the tension regulating driver (servo driver), which drives the motor of the cable storage device to perform corresponding actions: when the cable tension is too high, the cable storage device swings upward to release the cable; when the cable tension is too low, the cable storage device swings downward to absorb the cable, thereby maintaining constant tension. During the reel changing process, this algorithm also works. When the main reel decelerates, the cable storage device absorbs excess cable; when the standby reel starts, the cable storage device releases the cable, ensuring that tension fluctuations are minimized throughout the entire reel changing process.
[0028] This implementation method enables the tension adjustment algorithm to respond to tension changes in real time through PID closed-loop control, maintaining constant cable tension during normal production and reel changing processes, effectively avoiding cable stretching or loosening caused by tension fluctuations.
[0029] In this embodiment, the reel-changing timing coordination algorithm is used to achieve coordinated control of the cable take-up and cable laying actions and the reel-changing action. It maintains stable cable tension during the reel-changing process and automatically calibrates the synchronization parameters of the main take-up reel's rotation speed and cable laying displacement after the reel-changing is completed. The reel-changing timing coordination algorithm is based on the finite state machine principle and defines a complete reel-changing process state machine. The state machine includes the following six core states: State S0 is the normal take-up and cable laying state, where the system is in normal production mode, and the take-up and cable laying synchronization control algorithm and tension adjustment algorithm are working normally; State S1 is the reel change preparation state, where the main take-up reel decelerates at a preset slope after the reel change is triggered, and the cable storage device preloads tension compensation; State S2 is the cable guide switching state, where when the main take-up reel speed drops to a preset threshold and the cable layup device reaches the preset tape application position, the guide device is activated to switch the cable from the main reel position to the standby reel position; State S3 is the cable cutting and fixing state, where the cable cutting and fixing actions are executed sequentially after the cable arrival signal feedback; State S4 is the standby reel activation state, where the standby reel accelerates to the normal take-up speed, and the cable storage device releases the stored cable to compensate for tension changes; State S5 is the post-reel change recovery state, where the system returns to the normal take-up and cable laying mode after the standby reel speed reaches the set value, and the full reel transfer and empty reel loading processes are triggered simultaneously.
[0030] In the application embodiment, the state transition is triggered by a specific event, and the specific transition logic is as follows: when in state S0 and the spool full detection sensor is triggered, the system transitions to state S1, and simultaneously sends a deceleration command to the take-up motor driver. The deceleration slope is preset to a (m / min). 2The system sends a preload command to the tension adjustment driver, positioning the cable storage device in the middle position to allow for tension compensation space. When in state S1, the take-up reel speed is less than or equal to the preset deceleration threshold, and the cable position sensor feedback value is equal to the preset tape application position, it transitions to state S2 and simultaneously sends a guide switching command to the product guide driver. When in state S2, and the guide device positioning sensor provides a valid signal, it transitions to state S3 and executes the following sequentially: sending a cable cutting command to the actuator driver, followed by a cable fixing command after a delay of Δt1 (e.g., 50 milliseconds); when in state S2... When the pneumatic clamping sensor in state S3 provides a valid signal, the system transitions to state S4. Simultaneously, an acceleration command is sent to the take-up motor driver of the spare reel, matching the acceleration and deceleration rates. A release command is also sent to the tension adjustment driver, causing the wire storage device to gradually return to the intermediate position. When the system is in state S4 and the spare reel reaches the normal take-up speed, the system transitions to state S5. Simultaneously, full reel transfer and empty reel loading commands are sent to the automated guided vehicle and the reel lifting driver. When the system is in state S5 and the empty reel loading sensor provides a valid signal, the system returns to state S0, completing the entire reel changing cycle.
[0031] In this embodiment, the reel-changing timing coordination algorithm also includes a time synchronization mechanism and a parameter calibration mechanism. The time synchronization mechanism uses a unified system clock to timestamp each action and monitors the completion status of actions through a preset time window. For example, the cable cutting action must be completed within 200 milliseconds after entering state S3; if this timeout occurs, a fault alarm is triggered. The cable fixing action must be completed within 100 milliseconds after cutting to ensure that the cable end does not retract under tension. The parameter calibration mechanism is automatically executed after the reel change: the system collects data on the take-up reel speed and cable guide displacement during the first cable laying cycle after the reel change, calculates the actual synchronization error = |actual cable laying position - theoretical cable laying position|, and if the actual synchronization error exceeds a preset threshold (e.g., ±0.1 mm), it automatically adjusts the speed compensation coefficient of the cable laying motor driver to restore the take-up and laying synchronization accuracy to the normal range. Simultaneously, the system records various timing parameters of this reel change (e.g., deceleration time, guide switching time, cutting response time, etc.) to dynamically optimize the preset timing values for the next reel change, achieving a self-learning function.
[0032] This implementation method enables the reel-changing timing coordination algorithm to precisely control the timing transitions at each stage of the reel-changing process using a finite state machine. Combined with a time synchronization mechanism, it ensures the timeliness and reliability of the actions, and a parameter calibration mechanism guarantees rapid restoration of high-precision synchronization after the reel change. This algorithm achieves seamless integration between the cable take-up and reel-changing actions, dynamically adjusting tension to maintain stability during the reel-changing process, fundamentally solving the problems of tension fluctuations and synchronization deviations caused by timing chaos during reel changing. Through self-learning optimization, the reel-changing timing parameters can adapt to different cable specifications and production conditions, further enhancing the system's intelligence level.
[0033] The drive module 102 is communicatively connected to the core control module 101 and includes a take-up and lay-up drive unit for driving the take-up and lay-up operation, and an actuator driver for performing the reel-changing action.
[0034] As an optional implementation, the take-up and cable delivery drive unit includes a take-up motor driver, a cable delivery motor driver, a tension adjustment driver, a product guide driver, and a traction driver. Specifically: the take-up motor driver uses a frequency converter to drive the take-up motor for stepless speed regulation to adapt to different take-up speed requirements. The cable delivery motor driver uses a servo driver to drive the cable delivery motor for high-precision reciprocating motion, ensuring accurate control of the cable delivery pitch. The tension adjustment driver, also a servo driver, connects to the motor of the cable storage device, maintaining constant tension during normal take-up and delivery. During reel changes, it absorbs or releases cable through the left-right swinging of the cable storage device, compensating for the speed difference between the main reel's deceleration and the standby reel's startup. The product guide driver, also a servo driver, drives a ball screw slide to precisely guide the cable from the main take-up reel to the working position of the standby reel (i.e., empty reel). The traction driver uses a frequency converter to drive the track traction device, ensuring that the cable delivery speed is synchronized with the main machine speed, preventing cable accumulation or stretching.
[0035] This implementation method enables the take-up and lay-up drive unit to precisely control take-up, lay-up, tension adjustment, guide switching, and traction synchronization, providing stable and reliable power support for daily production operations.
[0036] As an optional implementation, the drive module 102 also includes a tape applicator, an automated guided vehicle (AGV), and a reel lifting driver. The tape applicator, a servo driver, drives the tape applicator mechanism to a designated position after the reel is full, securing the cable firmly to the reel and preventing it from coming loose during subsequent transport, ensuring safe transfer and storage. The AAV communicates wirelessly with the core control module 101 using the Modbus TCP protocol, forming a local area network with an industrial router. It is used to deliver empty reels to a location convenient for the take-up machine to automatically load them, and to transport full reels to a designated position. The reel lifting driver, also a servo driver, is used for loading and unloading the reels.
[0037] This implementation method automates the tape application and fixing process after tray change, as well as the transfer of full trays and loading of empty trays, further reducing manual intervention and creating a complete automated production closed loop.
[0038] As an optional implementation, the actuator driver employs an electromagnetic directional valve assembly to control the movement of actuators such as pneumatic shears (cable cutting mechanism) and pneumatic clamps (cable fixing mechanism). The electromagnetic directional valve assembly has a short response time, controllable within 100 milliseconds, ensuring rapid and accurate disc changing operations.
[0039] This implementation method enables the actuator driver to respond quickly to the reel-changing command, achieving instantaneous cutting and fixing of the cable, thus ensuring the timeliness and reliability of the reel-changing process.
[0040] The detection feedback module 103 is electrically connected to the core control module 101 and includes a cable take-up and cable run parameter detection unit for collecting cable take-up and cable run parameters, and a reel change status detection unit for collecting status signals during the reel change process.
[0041] As an optional implementation, the take-up and unwinding parameter detection unit includes a take-up position sensor and a speed sensor. The take-up position sensor uses an absolute encoder, mounted on the end of the take-up reel's lead screw, with a measurement accuracy of less than or equal to 0.01 mm, used for real-time feedback of the take-up reel's precise position. The speed sensor uses an incremental encoder, mounted on the take-up reel's shaft, with a resolution greater than or equal to 5000 lines per revolution, used for real-time feedback of the take-up reel's speed. Using data from these two sensors, the core control module 101 can precisely control the take-up and unwinding synchronization.
[0042] This implementation method enables the system to acquire high-precision position and speed information in real time, providing accurate feedback data for synchronous control of take-up and untake-up and tension adjustment, thus ensuring control accuracy during normal production.
[0043] As an optional implementation, the reel-changing status detection unit includes a reel fullness detection sensor and a reel positioning sensor. The reel fullness detection sensor is a diffuse reflection photoelectric sensor, mounted above the reel, with a detection distance of 150 mm to 800 mm. When the diameter of the cable wound on the reel reaches a set threshold (e.g., 700 mm), the sensor outputs a trigger signal. The reel positioning sensor is a proximity switch, mounted on the reel mounting base, with a positioning accuracy of less than or equal to 0.1 mm. It is used to detect whether the empty reel has been accurately pushed in and locked in the working position, ensuring the reliability of the reel-changing operation.
[0044] This implementation method enables the system to accurately detect whether the reel is full and whether the empty reel is in place, providing a reliable status criterion for reel change triggering and process control, avoiding false triggering or positioning deviation, and improving the reel change success rate.
[0045] The disk changing control module 104 is electrically connected to the core control module 101 and is used to receive instructions from the core control module 101 and drive the actuator to complete the disk changing action according to the instructions.
[0046] As an optional implementation, the reel-changing control module 104 includes a reel-changing logic processing unit, an actuator control unit, and a reel-changing status feedback unit. The reel-changing logic processing unit stores automatic reel-changing mode and manual-triggered reel-changing mode, and embeds a standardized reel-changing sequence flow: "full reel detection → winding deceleration → reel guiding movement → cable cutting → cable fixing → winding acceleration recovery." The automatic reel-changing mode is automatically triggered based on the signal from the reel full-reel detection sensor, suitable for continuous production; the manual-triggered reel-changing mode is triggered by commands issued through the human-machine interface module 105, suitable for equipment debugging or special working conditions. The actuator control unit directly controls the on / off state of the actuator driver (solenoid valve group) according to the commands from the core control module 101 to achieve precise control of pneumatic shears, pneumatic clamps, etc. The reel-changing status feedback unit feeds back signals from various limit switches, magnetic switches, and other sensors (such as shears in position, clamp clamping, etc.) to the core control module 101 in real time, ensuring that each step is confirmed before proceeding to the next step, forming a closed-loop control.
[0047] This implementation transforms the tray changing control module 104 into a dedicated intelligent unit for tray changing operations. The two tray changing modes built into the tray changing logic processing unit adapt to the different needs of automated production and manual debugging, while the standardized timing process ensures consistency in each tray changing action. The actuator control unit and the tray changing status feedback unit form a closed-loop control system, greatly improving the reliability and success rate of tray changing actions and effectively avoiding malfunctions caused by operational errors.
[0048] The human-machine interaction module 105 is communicatively connected to the core control module 101 and is used to realize parameter setting, status display and fault alarm.
[0049] As an optional implementation, the human-machine interface module 105 uses an industrial touchscreen. Specifically, a Weintek CMT2167X industrial touchscreen with a size of 15.6 inches can be used. The touchscreen interface includes a parameter setting area, a status display area, and a fault alarm area. The parameter setting area is used to set parameters such as take-up speed, cable pitch, full reel diameter threshold, tension setting, and reel changing speed. The status display area displays information such as the current take-up reel diameter, cable tension, equipment operating status, reel changing progress, and main / standby reel working status in real time in graphical and numerical form. In the fault alarm area, when faults such as cable cutting failure, inaccurate reel positioning, or tape application failure occur, an alarm window immediately pops up, a fault log is recorded, and an audible and visual alarm can be triggered to alert the operator.
[0050] This implementation method makes the human-machine interface module 105 an efficient communication bridge between operators and equipment. The intuitive interface design and centralized parameter management reduce operational difficulty and the risk of misoperation. Real-time status display and timely fault alarms allow operators to fully grasp the equipment's operating status and respond quickly in case of anomalies, improving the equipment's maintainability and safety.
[0051] In the embodiments of this application, such as Figures 2 to 5 As shown, the electronic control system works closely with the mechanical structure of the cable take-up and cable laying machine. Figure 2 The overall mechanism of the cable take-up and cable laying machine is shown, including a left take-up device 2, a right take-up device 4, a guide device 3, a cable storage device 5, a left tape application device 7, a right tape application device 6, and a tracked traction device 8. The cable 1 (cable) travels through these devices, and the tracked traction device 8 provides the driving force for the cable's movement. The core control module 101 coordinates the actions of these mechanical components through the drive module 102.
[0052] As an optional implementation method, such as Figures 3 to 5 As shown, the process of changing from the right take-up device 4 to the left take-up device 2 is used as an example to illustrate the working process. Figure 3 This indicates that the right take-up device 4 is in the take-up state. When the spool full detection sensor installed above the right take-up device 4 detects that the spool diameter has reached a preset value (e.g., Figure 4 When the system switches to the left take-up device 2 for operation (as shown in the diagram), the core control module 101 triggers the automatic reel-changing process. At this time, the core control module 101 controls the guide device 3 via the product guide driver to smoothly guide the cable 1 from the right take-up device 4 side to the empty reel on the left take-up device 2 side (as shown in the diagram). Figure 5 (As shown). During this process, the cable storage device 5, under the control of the tension regulating driver, stores or releases the cable by swinging up and down to compensate for the speed difference during the reel changing process, ensuring that the cable 1 is always under constant tension. When the cable 1 contacts the empty reel on the left take-up device 2 (as shown). Figure 5 As shown in the diagram, the actuator driver controls the pneumatic clamp to quickly secure the cable end in the empty cable reel slot, while the pneumatic shears cut the cable. Subsequently, the left take-up device 2 accelerates to the normal take-up speed, while the full reel on the right take-up device 4 is removed and transported away by the automated guided vehicle and the reel lifting driver, while a new empty reel is loaded, awaiting the next reel change instruction.
[0053] In this embodiment, after the cable winding operation is completed (full reel), the core control module instructs the tape applicator to drive the left tape applicator 7 or the right tape applicator 6 to advance to the full reel position to perform the tape applicator operation, firmly attaching and fixing the cable ends to the full reel to prevent the cables from loosening during transportation and storage. After the tape applicator is completed, the automatic guided transport vehicle and the reel lifting driver work together to remove the full reel and transport it away.
[0054] This implementation method enables the entire reel-changing process to be fully automated and unattended. From full reel detection, reel-changing triggering, cable guidance switching, tension compensation, cable cutting and fixing, to full reel transfer and empty reel loading, all steps are completed automatically by the system, completely eliminating the need for manual intervention. The reel-changing time is shortened to less than 30 seconds, significantly improving production efficiency.
[0055] In one exemplary embodiment, such as Figure 6 As shown, an electronic control method for a fully automatic reel-changing take-up and cable-laying machine is also provided, applied to the aforementioned electronic control system, comprising the following steps 201 to 205, wherein: Step 201: Set the cable winding operation parameters and reel change trigger parameters through the human-machine interaction module 105.
[0056] In this embodiment, parameters such as take-up speed, cable pitch, tension setting, and full-reel diameter threshold are set via the touchscreen of the human-machine interface module 105. Operators can flexibly adjust these parameters according to different cable specifications and production requirements.
[0057] This implementation method allows operators to flexibly adjust equipment operating parameters according to different production tasks, meeting diverse production needs. The parameter preset step lays the foundation for subsequent automated operation, ensuring that the equipment operates according to the expected process requirements.
[0058] Step 202: The core control module 101 controls the drive module 102 to perform cable winding and laying operations based on the real-time signal collected by the detection feedback module 103, and the tension adjustment algorithm maintains the cable tension stability.
[0059] In this embodiment, the core control module 101, based on real-time feedback from the cable position sensor and speed sensor, accurately calculates and outputs commands to the take-up motor driver and the cable delivery motor driver through a take-up-and-delivery synchronization control algorithm, ensuring precise matching between the take-up reel speed and the cable delivery device displacement. Simultaneously, the tension adjustment algorithm dynamically adjusts the tension adjustment driver based on feedback from the tension sensor (which can be integrated into the cable storage device), maintaining constant cable tension.
[0060] This implementation method ensures that the equipment maintains high-precision and stable operation during normal production. The core control module 101 precisely controls the synchronous operation of the take-up motor and the cable-laying motor based on real-time feedback from high-precision sensors, ensuring neat cable arrangement and constant tension, thus guaranteeing product quality.
[0061] Step 203: When the status signal collected by the detection feedback module 103 meets the preset disk replacement triggering conditions, the core control module 101 triggers the disk replacement process.
[0062] In this embodiment of the application, when the full-reel detection sensor detects that the diameter of the main take-up reel has reached the preset full-reel diameter threshold, or when a manual reel-changing command is received through the human-machine interaction module 105, the core control module 101 triggers the reel-changing process.
[0063] This implementation method combines automation and flexibility in the disc-changing triggering mechanism. The automatic triggering mode meets the needs of continuous production, while the manual triggering mode provides a convenient option for equipment debugging, maintenance, or operation under special conditions, enhancing the adaptability of the electrical control system.
[0064] Step 204: The core control module 101 coordinates and controls the drive module 102 and the reel-changing control module 104 to sequentially complete the actions of main take-up reel deceleration, cable guidance switching, cable cutting, and cable fixing to the spare reel according to the preset reel-changing sequence.
[0065] In this embodiment, the core control module 101 instructs the take-up motor of the main take-up reel to decelerate at a preset slope, while the tension regulating driver controls the cable storage device to absorb excess cable to maintain tension. Then, the product guide driver drives the guide device to smoothly guide the cable from the main reel position to the empty reel position of the spare reel. After the cable is in place, the actuator driver drives the pneumatic shears to cut the cable and immediately drives the pneumatic clamp to fix the cable end in the slot of the spare reel.
[0066] This implementation method ensures precise and controllable operation at every step of the reel-changing process. The main take-up reel decelerates and tension compensation simultaneously, preventing cable slack or stretching; the cable guide switching transitions smoothly, ensuring the cable accurately enters the working position of the spare reel; cable cutting and securing are completed rapidly, with a response time of less than or equal to 100 milliseconds. The entire reel-changing process is continuous, precise, and stable.
[0067] In step 205, the core control module 101 switches the spare reel that has been wired to the main take-up reel, resumes the take-up and wiring operation, and controls the automatic guided transport vehicle and the reel lifting driver to complete the transfer of full reels and the loading of empty reels.
[0068] In this embodiment, the automated guided vehicle and the core control module 101 communicate wirelessly using the Modbus TCP protocol and form a local area network using an industrial router to achieve automatic scheduling of full and empty disks.
[0069] This implementation method allows the equipment to quickly resume production and simultaneously complete material flow. The take-up speed is immediately restored after the spare reel switches to the main reel, minimizing the impact of reel changes on production efficiency. The coordinated operation of the automated guided vehicle and the reel lifting drive enables automated transfer and unloading of full and empty reels, further reducing manual intervention and creating a complete automated production closed loop.
[0070] It should be noted that the specific mechanical structure of the cable take-up and cable laying machine involved in this application can be found in the invention patent filed by the same applicant on the same day, entitled "A cable take-up and cable laying machine and cable take-up and cable laying method".
[0071] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0072] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.
Claims
1. An electrical control system for a fully automatic reel-changing and take-up cable machine, characterized in that, The electronic control system of the fully automatic reel-changing and take-up cable machine includes: The core control module is used to coordinate the cable take-up and cable run-up actions and the reel changing process. It has built-in cable take-up and cable run-up synchronization control algorithm, tension adjustment algorithm and reel changing timing coordination algorithm. The drive module is communicatively connected to the core control module. The drive module includes a take-up and lay-up drive unit for driving the take-up and lay-up operation, and an actuator driver for performing the reel-changing action. The detection feedback module is electrically connected to the core control module. The detection feedback module includes a cable take-up and cable run-up parameter detection unit for collecting cable take-up and cable run-up parameters, and a reel change status detection unit for collecting status signals during the reel change process. The disk changing control module is electrically connected to the core control module. The disk changing control module is used to receive instructions from the core control module and drive the actuator to complete the disk changing action according to the instructions. The human-machine interaction module is communicatively connected to the core control module. The human-machine interaction module is used to realize parameter setting, status display and fault alarm.
2. The electrical control system of the fully automatic reel-changing and take-up cable machine according to claim 1, characterized in that, The core control module adopts a programmable logic controller with process fieldbus and high-speed input / output interface. The core control module communicates bidirectionally with the drive module, the detection feedback module, the disk changing control module and the human-machine interaction module through the process fieldbus.
3. The electrical control system of the fully automatic reel-changing and take-up cable machine according to claim 1, characterized in that, The cable take-up and delivery drive unit includes: Take-up motor driver, used to drive the take-up reel to rotate; Cable driver, used to drive the cable reciprocating motion; Tension adjustment driver, used to adjust and maintain cable tension during take-up and reel changing; Product-oriented drive, used to switch the position of the cable between the main take-up reel and the spare reel; A traction drive is used to drive the traction device to achieve speed synchronization with the host machine.
4. The electrical control system of the fully automatic reel-changing take-up and cable-laying machine according to claim 3, characterized in that, The driver module also includes: Tape applicator driver, used to drive the tape applicator mechanism to complete the tape applicator operation; Automated guided vehicles are used to automate the transfer of full and empty pallets. A reel lifting drive is used to drive the loading and unloading of the reel.
5. The electrical control system of the fully automatic reel-changing and take-up cable machine according to claim 1, characterized in that, The cable take-up parameter detection unit includes: Cable position sensor is used to detect the real-time position of the cable connector; A speed sensor is used to detect the real-time speed of the take-up reel; The disk changing status detection unit includes: The cable reel fullness detection sensor is used to detect whether the cable reel is full. The spool positioning sensor is used to detect whether an empty spool has been installed in a preset position.
6. The electrical control system of the fully automatic reel-changing and take-up cable machine according to claim 5, characterized in that, The full-reel detection sensor is a diffuse reflection photoelectric sensor, installed above the take-up reel; the reel positioning sensor is a proximity switch, installed on the reel mounting base.
7. The electrical control system of the fully automatic reel-changing and take-up cable machine as described in claim 1, characterized in that, The disk changing control module includes: The disk swapping logic processing unit is used to store and execute preset disk swapping modes and disk swapping timing processes; An actuator control unit is used to drive the actuator driver to operate according to the instructions of the core control module; The disk changing status feedback unit is used to feed back the status signals of each stage during the disk changing process to the core control module in real time.
8. The electrical control system of the fully automatic reel-changing take-up and cable-laying machine according to claim 7, characterized in that, The reel-changing modes include an automatic reel-changing mode that is automatically triggered based on the full reel signal, and a manual reel-changing mode that is triggered by instructions from the human-machine interaction module.
9. An electrical control method for a fully automatic reel-changing take-up and cable laying machine, applied to the electrical control system of the fully automatic reel-changing take-up and cable laying machine according to any one of claims 1 to 8, characterized in that, The electronic control method of the fully automatic reel-changing and take-up cable machine includes: The parameters for cable reeling and reel changing can be set via the human-computer interaction module. The core control module controls the drive module to perform cable winding and laying operations based on the real-time signals collected by the detection feedback module, and the tension adjustment algorithm maintains stable cable tension. When the status signal collected by the detection feedback module meets the preset disk replacement triggering conditions, the core control module triggers the disk replacement process. The core control module coordinates and controls the drive module and the reel-changing control module to sequentially complete the actions of main take-up reel deceleration, cable guidance switching, cable cutting, and cable fixing to the spare reel according to the preset reel-changing sequence. The core control module switches the backup reel that has been wired to the main take-up reel, resumes the take-up and wire laying operation, and controls the automatic guided transport vehicle and the reel lifting drive to complete the transfer of full reels and the loading of empty reels.
10. The electrical control method for the fully automatic reel-changing and take-up cable machine according to claim 9, characterized in that, The reel-changing trigger conditions include: the reel full-reel detection sensor detecting that the diameter of the main take-up reel has reached a preset full-reel diameter threshold, or receiving a manual reel-changing command issued through the human-machine interaction module.