Combined signal power cable production process parameter monitoring method and system

Abstract

The invention relates to the field of cable manufacturing process control, in particular to a combined signal power cable production process parameter monitoring method and system. The method comprises the following steps: carrying out space-time backtracking on a real-time traction speed sequence, constructing a process state data set in which the machine head temperature, the first-section cooling water tank temperature and the traction speed are synchronous, and solving the problem of space-time dislocation of data in different places. Calculating the dynamic thermal shock strength of the cable slice according to the effective heat exchange length of the water tank and the temperature difference between the machine head and the water tank; in combination with the heterogeneous radial ratio of the large-section power line core and the small-section signal line core, through a thermal shrinkage sensitivity coefficient and a tension fluctuation coupling coefficient, the thermal shock strength and the speed fluctuation rate are subjected to weighted coupling, and a radial mismatch index is obtained to represent the internal extrusion risk. When the index exceeds a threshold value, PID temperature rise adjustment is carried out on the first section of cooling water tank, thermal-force mismatching of an external insulating layer and a cable core is quantified, internal invisible defects are eliminated, and stable electrical performance of the cable is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing process control, and in particular to a method and system for monitoring process parameters in the production of combined signal power cables. Background Technology

[0002] In the extrusion production of fiber optic composite cables or combined signal and power cables, the cable structure is typically composed of large-section power conductors and fine signal conductors twisted together, with an external insulation layer for the signal conductors extruded. Currently, the mainstream method for monitoring cable extrusion quality in industrial settings is to use a laser diameter gauge to monitor the outer diameter and ellipticity of the signal conductor insulation layer online.

[0003] However, this monitoring method based on external geometry has significant limitations in actual production, as it cannot effectively identify the risk of physical damage inside the cable. This is mainly because there are huge differences in the physical characteristics of power conductors and signal conductors: power conductors have a high metal content and large heat capacity, acting like a huge heat storage body, and dissipate heat very slowly; while signal conductors and the outer polymer signal conductor insulation layer have a small heat capacity and cool down extremely quickly when exposed to water.

[0004] When the high-temperature cable enters the cooling water tank, the insulation layer of the signal core cools rapidly and hardens, forming a rigid outer shell. At this time, the internal power core remains in a state of high temperature expansion. As the production line moves forward, the signal core gradually releases heat and begins to shrink in volume. Because the insulation layer of the signal core has already hardened and solidified, the shrinkage of the power core cannot cause the insulation layer of the signal core to shrink inward as a whole. This results in the tensile force generated by the shrinkage acting directly on the fragile signal core, or causing severe radial compression between the power core and the signal core.

[0005] This internal compression phenomenon caused by external cooling and internal heating often leads to increased fiber micro-bending loss or deformation of the signal line insulation layer under pressure, severely affecting the signal transmission performance of the finished product. However, during this process, the external dimensions of the cable usually remain unchanged, and the data displayed by the laser diameter gauge still appears to be within acceptable limits. This hidden defect, where the outer diameter is acceptable but the inner core is damaged, prevents production personnel from detecting the problem in the manufacturing process. Often, the excessive signal attenuation is only discovered after finished product inspection or even after installation and use, resulting in significant economic losses. Therefore, the industry urgently needs a process parameter monitoring method that can directly quantify and assess the risk of internal core compression by looking beyond the surface appearance of the signal core insulation layer. Summary of the Invention

[0006] To address the problem that existing outer diameter monitoring technologies cannot detect internal hidden extrusion defects caused by differences in heat dissipation of the wire core, this invention provides a method and system for monitoring parameters during the production process of combined signal power cables.

[0007] In a first aspect, the present invention provides a method for monitoring parameters during the production process of combined signal power cables, employing the following technical solution: A method for monitoring process parameters in the production of combined signal power cables, comprising the following steps: Collect real-time traction speed, extruder head temperature, and first-stage cooling water tank temperature on the production line, and construct a synchronous process status data group; The effective heat exchange length of the first cooling water tank is obtained, and the dynamic thermal shock intensity is calculated based on the synchronous process state data group. The dynamic thermal shock intensity is positively correlated with the temperature difference between the machine head and the water tank and negatively correlated with the effective heat exchange length. Obtain the heterogeneous radial ratio of the power conductor and the signal conductor, as well as the process reference speed. Using the thermal shrinkage sensitivity coefficient and the tension fluctuation coupling coefficient, the dynamic thermal shock intensity, the heterogeneous radial ratio, and the fluctuation rate of the real-time traction speed relative to the reference speed are weighted and calculated to obtain the radial mismatch index characterizing the internal extrusion risk. When the radial mismatch index is greater than a preset safety threshold, a temperature adjustment command is generated for the first cooling water tank. The cooling water temperature is adjusted using a PID algorithm to achieve monitoring of process parameters in the production of combined signal power cables.

[0008] This invention calculates a radial mismatch index that reflects the internal physical state by collecting process parameters such as temperature and speed. This radial mismatch index directly describes the degree of thermodynamic conflict between the signal core insulation layer and the signal core during the cooling process, enabling the control system to detect the risk of compression in advance and automatically adjust the cooling process before the signal core is actually damaged, thereby eliminating hidden internal defects.

[0009] Preferably, the synchronous process status data set includes the historical time when the cable slice that entered the first cooling water tank at the current sampling time leaves the extruder head, and its specific calculation method includes:

[0010] In the formula, i is the index number of the cable slice entering the first cooling water tank at the current sampling time, and t represents the sampling time. This indicates the fixed physical distance from the extruder head to the first cooling water tank. This indicates the time when the i-th cable slice enters the first section of the cooling water tank. This represents the historical moment when the i-th cable slice leaves the extruder head. This represents the traction velocity at sampling time t; Based on the above relationship, the historical moment when the i-th cable segment leaves the extruder head can be obtained by inverse solving. .

[0011] This invention uses an integral algorithm to pinpoint the actual physical location of each meter of cable, ensuring that the machine head temperature and water tank temperature used for risk calculation are indeed applied to the same section of cable, thus avoiding false alarms caused by data misalignment.

[0012] Preferably, the formula for calculating the dynamic thermal shock intensity is:

[0013] In the formula, Indicates the first Dynamic thermal shock strength of individual cable slices Indicates the production of the first The head temperature of a single cable slice at a historical moment. Indicates the first The temperature of the first segment of the cooling water tank of each cable slice at the current sampling time. This indicates the effective heat transfer length. Indicates the first Real-time traction speed of each cable slice This represents the cross-sectional shape correction factor.

[0014] This invention utilizes dynamic thermal shock intensity to objectively reflect the instantaneous hardening rate of the sheath surface. The greater the thermal shock intensity, the faster the insulation layer of the outer signal core hardens, the smaller the natural shrinkage space left for the inner signal core, and the higher the probability of subsequent internal extrusion, thus providing a thermal basis for risk assessment.

[0015] Preferably, the formula for calculating the radial mismatch index is:

[0016] In the formula, Indicates the first Radial mismatch index of a cable slice, Indicates the thermal shrinkage sensitivity coefficient. Indicates dynamic thermal shock intensity. Indicates the nominal diameter of the power conductor core. Indicates the nominal diameter of the signal wire core. This represents the tension fluctuation coupling coefficient. Indicates real-time traction speed. Indicates the reference speed, This represents absolute value operations.

[0017] This invention considers not only the compressive force caused by thermal expansion and contraction when calculating the radial mismatch index, but also the axial tension caused by traction speed fluctuations, which can comprehensively and accurately characterize the comprehensive stress risk borne by the signal core under complex working conditions.

[0018] Preferably, the method for obtaining the heat shrinkage sensitivity coefficient includes: During the trial production stage, the production line traction speed is kept constant, and the temperature of the first cooling water tank is adjusted in stages to calculate the dynamic thermal shock intensity at different cooling water tank temperatures; the deformation rate of the signal core insulation layer is measured after the cable is cooled; a linear regression algorithm is used to fit the straight line between the deformation rate and the dynamic thermal shock intensity, and the slope of the straight line is determined as the thermal shrinkage sensitivity coefficient.

[0019] Preferably, the method for obtaining the tension fluctuation coupling coefficient includes: Under constant temperature conditions, a sinusoidal velocity disturbance is introduced, and the corresponding rate of change of axial tension is measured. Calculate the ratio of the axial tension change rate to the velocity fluctuation rate, and determine the ratio as the tension fluctuation coupling coefficient.

[0020] Preferably, the method for obtaining the preset security threshold includes: Obtain the radial mismatch index and finished product electrical performance test reports from historical production data; The radial mismatch index corresponding to when the signal transmission attenuation of the finished product reaches the upper limit of the national standard is selected as the critical value; The preset safety threshold is obtained by multiplying the critical value by a preset safety factor.

[0021] Preferably, before generating the temperature adjustment command for the first cooling water tank, a device safety protection step is also included: Obtain the target set water temperature corresponding to the first cooling water tank temperature rise adjustment command; If the target set water temperature is higher than the equipment's tolerance limit temperature, the final target set water temperature will be forced to the equipment's tolerance limit temperature and an alarm will be triggered. If the target water temperature is lower than the workshop ambient temperature, the final target water temperature will be forced to be the sum of the workshop ambient temperature and the preset safety margin.

[0022] This invention ensures that the automatic control logic does not exceed the physical limits of the equipment, prevents damage to the water pump due to excessively high water temperature or moisture damage to the cables due to excessively low water temperature, and guarantees the continuity and safety of the production process.

[0023] Preferably, the method for obtaining the cross-sectional shape correction coefficient includes: Calculate the ratio of the cable's outer perimeter to the circumference of a standard circle of the same area, and use this ratio as a cross-sectional shape correction factor.

[0024] Secondly, this invention provides a process parameter monitoring system for combined signal power cables, employing the following technical solution: A process parameter monitoring system for combined signal power cable production includes a processor and a memory. The memory stores computer program instructions, which, when executed by the processor, implement the aforementioned method for monitoring process parameters of combined signal power cable production.

[0025] By adopting the above technical solution, a computer program is generated from the above-mentioned method for monitoring process parameters of combined signal power cables, and stored in a memory for loading and execution by a processor. Terminal equipment is then manufactured based on the memory and processor for convenient use.

[0026] The present invention has the following technical effects: This invention solves the industry problem that traditional outer diameter detection methods cannot detect cables that are intact on the outside but damaged on the inside. By calculating the radial mismatch index, it achieves an accurate description of the hidden extrusion risk inside the cable. Furthermore, this invention integrates the analysis of thermal shrinkage risk and mechanical tension risk, which can more accurately predict the electrical signal transmission performance of finished cables compared to single temperature monitoring or speed monitoring. Furthermore, the closed-loop control strategy proposed in this invention can proactively intervene in the cooling process of extrusion production, and alleviate internal thermal stress by dynamically adjusting the water temperature, thereby significantly reducing the scrap rate of high-value optoelectronic composite cables. Attached Figure Description

[0027] Figure 1 This is a flowchart of a method for monitoring process parameters in the production of combined signal power cables according to an embodiment of the present invention; Figure 2 The above is a comparison chart of the detection effects of hidden defects provided in the embodiments of the present invention. Detailed Implementation

[0028] This invention discloses a method for monitoring parameters during the production process of combined signal power cables, referring to... Figure 1 This includes steps S1-S4: S1: Collect real-time traction speed, extruder head temperature and first-stage cooling water tank temperature on the production line, and construct a synchronous process status data group.

[0029] It's important to note that in continuous extrusion production, there's a fixed physical distance between the extruder head and the first cooling water tank, while the production line's traction speed typically fluctuates dynamically. If data is collected only at the current point in time, these two entities do not physically belong to the same cable segment. This spatiotemporal misalignment can lead to causal inversion in subsequent correlation analyses. Therefore, the core logic of this step is to eliminate the nonlinear lag caused by speed fluctuations, tracing back and anchoring heterogeneous data collected at different time points to the same physical segment of the cable, ensuring that subsequent multidimensional coupling analyses have a true physical correspondence.

[0030] Preferably, as an example, the real-time traction speed, extruder head temperature, and first-stage cooling water tank temperature on the production line are collected, and a synchronous process status data set is constructed, including: First, the real-time traction speed, extruder head temperature, and first-stage cooling water tank temperature are acquired from the sensor array.

[0031] Next, we construct the relationship between traction speed and distance traveled:

[0032] In the formula, i is the index number of the cable slice entering the first cooling water tank at the current sampling time, and t represents the sampling time. This indicates the fixed physical distance from the extruder head to the first cooling water tank. This indicates the time when the i-th cable slice enters the first section of the cooling water tank. This represents the historical moment when the i-th cable slice leaves the extruder head. This represents the traction velocity at sampling time t; Based on the above relationship, the historical moment when the i-th cable segment leaves the extruder head can be obtained by inverse solving. .

[0033] Understandably, simple linear time estimation would produce significant errors under variable speed conditions. Therefore, by performing an inverse Riemann integral on the speed sequence, the physical path the cable travels on the production line is calculated, and the moment when the current segment of cable entering the water tank is extruded from the die head is deduced. This ensures that the die head temperature used in subsequent steps is indeed the true temperature of that segment of cable in its molten state, eliminating spatiotemporal misalignment at the data source.

[0034] It should be noted that the method for obtaining the fixed physical distance includes: with the production line stopped and the cooling water tank drained, using a high-precision handheld laser rangefinder to measure the straight-line distance from the center of the extruder die outlet end face to the inner side of the inlet baffle of the first cooling water tank, thus obtaining the fixed physical distance.

[0035] Finally, based on the aforementioned historical moments Extract the corresponding head temperature The temperature of the machine head The current water tank temperature and real-time traction speed Perform correlation processing to obtain a synchronized process status data group. .

[0036] S2: Obtain the effective heat exchange length of the first cooling water tank, and calculate the dynamic thermal shock intensity based on the synchronous process state data group. The dynamic thermal shock intensity is positively correlated with the temperature difference between the machine head and the water tank and negatively correlated with the effective heat exchange length.

[0037] It should be noted that there is a severe thermal shock window the moment the cable enters the water tank. Within this window, the high-temperature signal core insulation layer rapidly comes into contact with the low-temperature water flow, transforming from a viscous state to a highly elastic state or even a glassy state, forming a cold, hard shell. The formation rate of this shell directly determines the external binding strength experienced by the subsequent signal core contraction. Therefore, the logic of this step is to construct an index that can characterize the instantaneous hardening rate, thereby objectively evaluating the degree of hardening of the signal core insulation layer.

[0038] Preferably, as an example, obtaining the effective heat exchange length of the first cooling water tank and calculating the dynamic thermal shock intensity based on the synchronous process state data set includes:

[0039] In the formula, Indicates the first Dynamic thermal shock strength of individual cable slices Indicates the first The head temperature of a single cable slice at a historical moment. Indicates the first The temperature of the first segment of the cooling water tank of each cable slice at the current sampling time. This indicates the effective heat transfer length. Indicates the production of the first Real-time traction speed of each cable slice This represents the cross-sectional shape correction factor.

[0040] Understandable The term characterizes the spatial temperature gradient, with the numerator representing the temperature difference potential energy and the denominator representing the heat transfer distance. The larger the temperature difference or the shorter the distance, the steeper the temperature drop in space.

[0041] The term represents the time factor. The faster the traction speed of the cable production line, the shorter the time it takes for a unit length of cable to traverse the spatial gradient, resulting in a sharp increase in the rate of temperature change per unit time. This is the physical root cause of surface cracks or internal stress that easily occur in high-speed production.

[0042] The term characterizes the geometric correction. The specific surface area of ​​a non-circular cross section is usually larger than that of a standard circle, and its heat transfer efficiency is higher. Therefore, this coefficient is used to gain correction for impact intensity to reflect more intense cooling conditions.

[0043] It should be noted that the effective heat exchange length Methods for obtaining [the information] include: The effective heat exchange length is obtained by measuring the total length of the first cooling water tank and subtracting the overflow buffer length at the inlet and outlet.

[0044] It should also be noted that the cross-sectional shape correction factor Methods for obtaining [the information] include: The ratio of the cable's outer perimeter to the circumference of a standard circle of the same area is calculated as a cross-sectional shape correction factor.

[0045] S3: Obtain the heterogeneous radial ratio of the power conductor and the signal conductor, as well as the process reference speed. Using the thermal shrinkage sensitivity coefficient and the tension fluctuation coupling coefficient, perform a weighted calculation on the dynamic thermal shock intensity, the heterogeneous radial ratio, and the fluctuation rate of the real-time traction speed relative to the reference speed to obtain the radial mismatch index characterizing the internal extrusion risk.

[0046] It's important to note that physical defects essentially arise when internal stress exceeds the material's tolerance limit. Thermal shock is merely an external trigger; the real risk stems from the conflicting heterogeneous structures within the cable. Large-section power cores have high thermal capacity and delayed contraction; small-section signal cores have low thermal capacity and are fragile. When the insulation layer of the signal core hardens prematurely, locking the boundaries, the subsequent contraction of the internal power core transforms into inward compressive stress. Simultaneously, fluctuations in traction speed introduce oscillations in axial tension, further deteriorating the stress environment. This step describes the superimposed effect of thermal contraction and mechanical tension, thereby revealing the hidden internal damage risk.

[0047] Preferably, as an example, the heterogeneous radial ratio of the power conductor and the signal conductor, as well as the process reference speed, are obtained. Using the thermal shrinkage sensitivity coefficient and tension fluctuation coupling coefficient, a weighted calculation is performed on the dynamic thermal shock intensity, the heterogeneous radial ratio, and the fluctuation rate of the real-time traction speed relative to the reference speed to obtain a radial mismatch index characterizing the internal crush risk, including: First, obtain the nominal diameter of the power conductor, the nominal diameter of the signal conductor, and the reference speed set in the process from the production work order.

[0048] Next, the radial mismatch index is calculated, specifically satisfying the following relationship:

[0049] In the formula, Indicates the first Radial mismatch index of a cable slice, Indicates the thermal shrinkage sensitivity coefficient. Indicates dynamic thermal shock intensity. Indicates the nominal diameter of the power conductor core. Indicates the nominal diameter of the signal wire core. This represents the tension fluctuation coupling coefficient. Indicates real-time traction speed. Indicates the reference speed, This represents absolute value operations.

[0050] Understandable Item It is the external cooling rate. It is the structural amplification factor. The larger the value, the larger the power core, the higher its enthalpy, and the greater the volume change during cooling and contraction. The larger the value, the smaller the signal core and the weaker its pressure resistance. The larger the value, the greater the risk of the signal core being squeezed.

[0051] Item Characterized by the discrete fluctuation rate of speed, drastic speed fluctuations in the extrusion process directly lead to oscillations in the axial tension of the cable. According to the Poisson effect, axial stretching or relaxation instantly transforms into radial contraction or expansion, thereby exacerbating friction and misalignment between the internal wire cores.

[0052] In summary, This fully reflects the risk of signal cores being squeezed in a dynamic production environment.

[0053] It should be noted that the heat shrinkage sensitivity coefficient Methods for obtaining [the information] include: During the trial production phase, the production line traction speed was kept constant, and the temperature of the first-stage cooling water tank was adjusted in stages to calculate the dynamic thermal shock intensity at different temperatures. The deformation rate of the signal core insulation layer was measured after cable cooling. A linear regression algorithm was used to fit a straight line between the deformation rate and the dynamic thermal shock intensity, and the slope of this line was determined as the thermal shrinkage sensitivity coefficient. The deformation rate... , These are the maximum and minimum diameters of the cross-section of the insulation layer of the signal wire core, respectively.

[0054] It should also be noted that the tension fluctuation coupling coefficient Methods for obtaining [the information] include: Under constant temperature conditions, a sinusoidal velocity disturbance is artificially introduced; the corresponding axial tension change rate is measured using an online tension meter; the ratio of the axial tension change rate to the velocity fluctuation rate is calculated, and the ratio is determined as the tension fluctuation coupling coefficient, wherein the velocity fluctuation rate is equal to the ratio of the amplitude of the velocity disturbance to the real-time traction speed.

[0055] S4: When the radial mismatch index is greater than the preset safety threshold, a temperature adjustment command is generated for the first cooling water tank, and the cooling water temperature is adjusted using a PID algorithm to achieve monitoring of process parameters in the production of combined signal power cables.

[0056] It's important to note that the primary risk of physical defects in cables stems from excessively rapid cooling, leading to premature hardening of the signal core insulation. Therefore, a heating strategy is employed to reduce the cooling rate. Specifically, when the radial mismatch index exceeds the limit, a logical judgment indicates a high risk of internal compression. At this point, the temperature of the first water bath is actively increased to reduce the cooling rate of the signal core insulation, allowing it to remain in a viscoelastic state for a longer period. This flexible state allows the signal core insulation to adapt to the contraction of the signal core, releasing accumulated radial stress and eliminating compression on the signal core.

[0057] Preferably, as an example, when the radial mismatch index is greater than a preset safety threshold, a temperature adjustment command is generated for the first cooling water tank, and the cooling water temperature is adjusted using a PID algorithm to achieve monitoring of process parameters in the combined signal power cable production process, including: First, a preset safety threshold is obtained, and the difference between the radial mismatch index and the preset safety threshold is calculated to obtain the risk deviation value. The risk deviation value is then subjected to proportional, integral, and derivative operations using the PID algorithm to obtain the temperature regulation increment.

[0058] Obtain the set temperature of the first cooling water tank at the current moment, add the temperature adjustment increment to the set temperature to obtain a new target set water temperature, and generate a cooling water temperature adjustment command for the first cooling water tank based on the target set water temperature.

[0059] Understandably, when the radial mismatch index exceeds the safety threshold, it indicates an excessively high risk of internal compression. Increasing the water temperature setpoint using a PID algorithm can reduce the temperature difference term in the dynamic thermal shock intensity calculation formula, thereby directly reducing the dynamic thermal shock intensity. As the dynamic thermal shock intensity decreases, the radial mismatch index... The value of this item decreases accordingly, eventually bringing the total index back to a safe range. This process essentially sacrifices a small amount of cooling efficiency in exchange for a delay in the hardening rate of the signal core insulation layer, thus giving the signal core sufficient physical time to naturally shrink and avoiding damage to the signal core from force.

[0060] Finally, before issuing the adjustment command, the cooling water temperature adjustment command is amplitude clamped using the equipment safety protection logic to obtain the final target set water temperature, specifically including: Upper limit protection: If the target set water temperature is higher than the equipment's tolerance limit temperature, the final target set water temperature will be forced to the equipment's tolerance limit temperature and an alarm will be triggered.

[0061] Lower limit protection: If the target set water temperature is lower than the workshop ambient temperature, the final target set water temperature will be forced to be the sum of the workshop ambient temperature and the preset safety margin. For example, the preset safety margin is taken as... .

[0062] It should be noted that the methods for obtaining the preset security threshold include: Statistical analysis was performed on the historical production data of this type of cable, and the radial mismatch index sequence during the production process was correlated with the finished product electrical performance test report. The radial mismatch index corresponding to the signal transmission attenuation of the finished product reaching the upper limit of the national standard was selected from the finished product electrical performance test report as the critical value. The critical value was multiplied by a preset safety factor to obtain a preset safety threshold.

[0063] To demonstrate the effectiveness of the solution, relevant experiments were conducted. Below are the images obtained from the experiments: Figure 2 This is a comparison chart of the detection effects of hidden defects. The dotted line curve with circular markers represents the outer diameter monitoring index of the sheath in existing technologies; the thick solid line curve represents the radial mismatch index monitoring index proposed in this solution. The horizontal dotted line represents the preset safety threshold limit.

[0064] The images show that during changes in traction speed, the dotted line curve with circular markers, reflecting the prior art, remained on the baseline without significant fluctuations. This indicates that the prior art cannot detect internal structural changes caused by insufficient cooling.

[0065] During the same time period, the thick solid line curve reflecting this solution rapidly increased with speed and broke through the horizontal dotted line, accurately indicating the risk of internal crushing. In the latter half of the image, as the temperature control adjustment took effect, the thick solid line curve quickly fell back from its high position and eventually stabilized below the horizontal dotted line. This proves that the control method of this application can effectively suppress the risk indicator and bring it back to the safe range.

[0066] This invention also discloses a process parameter monitoring system for combined signal power cables, including a processor and a memory. The memory stores computer program instructions, and when the computer program instructions are executed by the processor, a process parameter monitoring method for combined signal power cables according to the present invention is implemented.

[0067] The system also includes other components well known to those skilled in the art, such as communication buses and communication interfaces, the settings and functions of which are known in the art and will not be described in detail here.

[0068] In this invention, the aforementioned memory can be any tangible medium containing or storing a program that can be used or combined with an instruction execution system, apparatus, or device. For example, a computer-readable storage medium can be any suitable magnetic or magneto-optical storage medium, such as resistive random access memory (DRAM), dynamic random access memory (DRAM), static random access memory (SRAM), enhanced dynamic random access memory (DRAM), high-bandwidth memory, hybrid memory cube, etc., or any other medium that can be used to store desired information and can be accessed by an application, module, or both. Any such computer storage medium can be part of a device or accessible to or connected to a device.

Claims

1. A method for monitoring process parameters in the production of combined signal power cables, characterized in that, Including the following steps: Collect real-time traction speed, extruder head temperature and first-stage cooling water tank temperature on the production line, and construct a synchronous process status data group; The effective heat exchange length of the first cooling water tank is obtained, and the dynamic thermal shock intensity is calculated based on the synchronous process state data group. The dynamic thermal shock intensity is positively correlated with the temperature difference between the machine head and the water tank and negatively correlated with the effective heat exchange length. Obtain the heterogeneous radial ratio of the power conductor and the signal conductor, as well as the process reference speed. Using the thermal shrinkage sensitivity coefficient and the tension fluctuation coupling coefficient, the dynamic thermal shock intensity, the heterogeneous radial ratio, and the fluctuation rate of the real-time traction speed relative to the reference speed are weighted and calculated to obtain the radial mismatch index characterizing the internal extrusion risk. When the radial mismatch index is greater than a preset safety threshold, a temperature adjustment command is generated for the first cooling water tank. The cooling water temperature is adjusted using a PID algorithm to achieve monitoring of process parameters in the production of combined signal power cables.

2. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, The synchronized process status data set includes the historical time when the cable slice that entered the first cooling water tank at the current sampling time leaves the extruder head. Its specific calculation method includes: In the formula, i is the index number of the cable slice entering the first cooling water tank at the current sampling time, and t represents the sampling time. This indicates the fixed physical distance from the extruder head to the first cooling water tank. This indicates the time when the i-th cable slice enters the first section of the cooling water tank. This represents the historical moment when the i-th cable slice leaves the extruder head. This represents the traction velocity at sampling time t; Based on the above relationship, the historical moment when the i-th cable segment leaves the extruder head can be obtained by inverse solving. .

3. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, The formula for calculating the dynamic thermal shock intensity is: In the formula, Indicates the first Dynamic thermal shock strength of individual cable slices Indicates the production of the first The head temperature of a single cable slice at a historical moment. Indicates the first The temperature of the first segment of the cooling water tank of each cable slice at the current sampling time. This indicates the effective heat transfer length. Indicates the first Real-time traction speed of each cable slice This represents the cross-sectional shape correction factor.

4. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, The formula for calculating the radial mismatch index is as follows: In the formula, Indicates the first Radial mismatch index of a cable slice, Indicates the thermal shrinkage sensitivity coefficient. Indicates dynamic thermal shock intensity. Indicates the nominal diameter of the power conductor core. Indicates the nominal diameter of the signal wire core. This represents the tension fluctuation coupling coefficient. Indicates real-time traction speed. Indicates the reference speed, This represents absolute value operations.

5. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, The method for obtaining the heat shrinkage sensitivity coefficient includes: During the trial production stage, the production line traction speed is kept constant, and the temperature of the first cooling water tank is adjusted in stages to calculate the dynamic thermal shock intensity at different cooling water tank temperatures; the deformation rate of the signal core insulation layer is measured after the cable is cooled; a linear regression algorithm is used to fit the straight line between the deformation rate and the dynamic thermal shock intensity, and the slope of the straight line is determined as the thermal shrinkage sensitivity coefficient.

6. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, The method for obtaining the tension fluctuation coupling coefficient includes: Under constant temperature conditions, a sinusoidal velocity disturbance is introduced, and the corresponding rate of change of axial tension is measured. Calculate the ratio of the axial tension change rate to the velocity fluctuation rate, and determine the ratio as the tension fluctuation coupling coefficient.

7. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, The method for obtaining the preset security threshold includes: Obtain the radial mismatch index and finished product electrical performance test reports from historical production data; The radial mismatch index corresponding to when the signal transmission attenuation of the finished product reaches the upper limit of the national standard is selected as the critical value; The preset safety threshold is obtained by multiplying the critical value by a preset safety factor.

8. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, Before generating the temperature adjustment command for the first cooling water tank, a device safety protection step is also included: Obtain the target set water temperature corresponding to the first cooling water tank temperature rise adjustment command; If the target set water temperature is higher than the equipment's tolerance limit temperature, the final target set water temperature will be forced to the equipment's tolerance limit temperature and an alarm will be triggered. If the target water temperature is lower than the workshop ambient temperature, the final target water temperature will be forced to be the sum of the workshop ambient temperature and the preset safety margin.

9. The method for monitoring process parameters in the production of combined signal power cables according to claim 1, characterized in that, The method for obtaining the cross-sectional shape correction coefficient includes: Calculate the ratio of the cable's outer perimeter to the circumference of a standard circle of the same area, and use this ratio as a cross-sectional shape correction factor.

10. A process parameter monitoring system for combined signal power cable production, characterized in that, include: A processor and a memory, the memory storing computer program instructions that, when executed by the processor, implement a method for monitoring process parameters of a combined signal power cable production process according to any one of claims 1-9.

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