Multi-specification heating wire precision winding device and control method thereof

Abstract

This invention relates to the field of precision winding automation equipment, specifically a precision winding device and control method for multi-specification heating wires; it includes modules for spindle winding, active wire feeding, micro-deformation monitoring, and control; the system generates feedforward control commands based on the skeleton geometric parameters and material rheological model; its core is to utilize an electronic cam and a constitutive equation inverse solver to construct a nonlinear mapping of the cross-section and calculate the wire strain state in real time; when the real-time strain exceeds the elastic deformation threshold, the system superimposes and sends a compensation torque command; this invention realizes the transformation from traditional mechanical hysteresis adjustment to model-based active predictive control, ensuring stress stability and production efficiency during high-speed winding of non-circular cross-section skeletons.

Description

Technical Field

[0001] This invention relates to the field of precision winding automation equipment, specifically to a precision winding device for multi-specification heating wires and its control method. Background Technology

[0002] In the precision manufacturing of multi-specification heating wires, the winding device needs to adapt to the processing requirements of different materials, wire diameters and non-circular cross-section skeletons, and has strict requirements on the internal stress state of the wire and the final resistance accuracy.

[0003] To achieve wire winding, existing solutions typically use mechanical friction plates or spring tensioners to establish a passive tension field and perform wire laying and feeding with fixed parameters based on the nominal diameter. Although such solutions have basic functionality in low-speed production of a single specification, they suffer from significant inertial lag and resonance risks due to their reliance on the passive response characteristics of physical mechanical structures. This makes it difficult to maintain constant tension during the intense speed fluctuations generated by high-speed winding of non-circular skeletons. Furthermore, traditional equipment lacks the ability to perceive the micro-rheological behavior of the wire and the radial necking effect in real time, and the changeover process heavily relies on repeated manual adjustments of mechanical parameters. This control mode, lacking material model support, makes it impossible to perform instantaneous stress release and dynamic wire laying compensation for wire hard points or knots. This can easily lead to wire breakage due to excessive plastic deformation, uneven wire density, and poor resistance consistency, severely limiting equipment utilization and finished product yield in multi-variety, small-batch production environments.

[0004] Therefore, how to construct an adaptive precision control system based on material constitutive properties and real-time deformation feedback to achieve high dynamic response and non-destructive winding under complex dynamic conditions has become an urgent technical problem to be solved. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides a precision winding device for multi-specification heating wires and its control method. Specifically, the technical solution of the present invention is as follows:

[0006] A precision winding device for multi-specification heating wires includes: a spindle winding unit for driving a winding skeleton to rotate; an active wire feeding unit for feeding wire to the spindle winding unit; a micro-deformation monitoring unit disposed between the spindle winding unit and the active wire feeding unit, and for real-time acquisition of radial dimension data of the wire; and a controller electrically connected to the spindle winding unit, the active wire feeding unit, and the micro-deformation monitoring unit. The controller is equipped with a material rheology model. Based on the geometric parameters of the winding skeleton and the material rheology model, the controller generates feedforward control commands for the active wire feeding unit. During the operation of the spindle winding unit, based on the radial dimension data fed back by the micro-deformation monitoring unit, the controller calculates the real-time strain state of the wire. When the real-time strain state exceeds a preset elastic deformation threshold, a compensation torque command is superimposed and sent to the active wire feeding unit.

[0007] Preferably, the controller includes a dynamic fingerprint library module, which stores constitutive equation parameters for wires of different specifications; the controller receives an externally input target resistance value and the material constant of the wire, and retrieves the corresponding yield strength threshold from the dynamic fingerprint library module as the elastic deformation threshold; the controller sets the maximum allowable radial shrinkage rate of the wire during the winding process based on the target resistance value and the material constant.

[0008] Preferably, the controller includes an electronic cam calculation module; the electronic cam calculation module constructs a nonlinear mapping relationship between the rotation angle and linear velocity of the spindle winding unit based on the cross-sectional shape data of the winding skeleton, and generates a velocity fluctuation curve; the controller uses the inverse constitutive equation operator to calculate the reverse acceleration required to counteract tension fluctuations based on the velocity fluctuation curve, and converts the reverse acceleration into the feedforward control command and sends it to the active wire feeding unit.

[0009] Preferably, the micro-deformation monitoring unit is a laser diffraction diameter gauge, which measures the diameter change of the wire using the principle of laser diffraction at a preset sampling frequency; the controller includes a strain analysis module, which receives the radial dimension data and calculates the current radial shrinkage rate of the wire; when the current radial shrinkage rate is greater than the shrinkage rate limit corresponding to the elastic deformation threshold, the controller determines that the wire has entered the plastic deformation zone and generates the compensation torque command to reduce the output impedance of the active wire feeding unit; when the current radial shrinkage rate is less than or equal to the shrinkage rate limit, the controller maintains the current control state of the active wire feeding unit.

[0010] Preferably, the controller includes a wiring compensation module; the wiring compensation module is communicatively connected to the micro-deformation monitoring unit, and adjusts the wiring pitch of the wiring mechanism in real time according to the changes in the radial dimension data to match the actual diameter of the wire under stress.

[0011] Preferably, both the active wire feeding unit and the spindle winding unit are driven by servo motors; the controller controls the active wire feeding unit and the spindle winding unit through a bus synchronization mechanism to establish a bidirectional active micro-differential motion relationship; the active wire feeding unit is configured as a simulated virtual spring damping system, and the stiffness coefficient of the virtual spring damping system is dynamically adjusted in real time by the controller according to the specifications of the wire.

[0012] Preferably, the device further includes: a memory electrically connected to the controller, used to record the radial dimension data and the historical curve of the real-time strain state during the winding process; the controller calculates the predicted resistance value after winding is completed online based on the historical curve and the elastic elongation of the wire, and performs the winding-detection function.

[0013] A control method for a precision winding device for multi-specification heating wires includes the following steps: constructing a stress-strain constitutive model of the wire and setting a maximum permissible radial shrinkage rate threshold according to the wire specifications; generating a nonlinear mapping relationship between the spindle rotation angle and linear velocity based on the geometry of the winding skeleton, and calculating the feedforward reverse acceleration of the active wire feeding unit accordingly; driving the active wire feeding unit to operate according to the feedforward reverse acceleration to counteract tension fluctuations caused by the geometry; detecting the radial dimension change of the wire in real time through a micro-deformation monitoring unit and calculating the real-time radial shrinkage rate; and comparing the real-time radial shrinkage rate with the maximum permissible radial shrinkage rate threshold. When the real-time radial shrinkage rate exceeds the maximum permissible radial shrinkage rate threshold, the output of the active wire feeding unit is corrected by superimposing a compensation torque. When the real-time radial shrinkage rate does not exceed the maximum permissible radial shrinkage rate threshold, the current feedforward control output is maintained.

[0014] Preferably, in the step of driving the active wire feeding unit, a virtual impedance control strategy is adopted; the controller adjusts the stiffness parameters of the virtual impedance model in real time according to the Young's modulus of the wire; when a hard point or knot is detected in the wire causing a sudden change in the real-time radial shrinkage rate, the damping value of the virtual impedance model is instantly reduced to release stress concentration.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] 1. This invention constructs a nonlinear mapping relationship for the geometric cross-sectional shape of the winding skeleton by using the electronic cam calculation module and the inverse constitutive equation operator in the controller. It generates feedforward control commands for the active wire feeding unit before tension fluctuations actually occur. This proactive control strategy based on the geometric model uses the active acceleration and deceleration of the motor to pre-counteract the periodic speed pulsations generated when the flat or irregularly shaped skeleton rotates. It overcomes the physical inertial lag and resonance risks of traditional mechanical friction plates or spring tensioners. Thus, even under the extreme working conditions of high-speed winding of non-circular cross-section skeletons, it can still ensure the stability of the internal stress of the wire and significantly improve production efficiency.

[0017] 2. This invention introduces a micro-deformation monitoring unit and a material rheology model, which can capture the radial dimensional changes and necking effect of the wire under dynamic stress in real time. When the radial shrinkage rate of the wire changes abruptly due to hard spots or knots and exceeds the elastic deformation threshold, the system determines that the wire is about to enter the plastic deformation zone and immediately sends a compensation torque command or instantly reduces the damping value of the virtual impedance model. This layered control strategy, similar to an airbag, can release concentrated stress in milliseconds, preventing the wire from breaking due to excessive plastic deformation, and achieving flexible containment and non-destructive winding of micro-defects.

[0018] 3. This invention stores constitutive equation parameters for wires of different specifications through a dynamic fingerprint library module within the controller, and uses a virtual spring damping system to replace physical springs. During production changeovers, the system eliminates the need for repeated manual adjustments to the mechanical structure. Instead, it automatically retrieves parameters such as Young's modulus based on the input target resistance and material constant, generates control boundaries that adapt to physical limits, and dynamically adjusts the virtual stiffness coefficient in real time. This data-driven parameter configuration method reduces changeover time from hours to seconds and eliminates the fatigue failure problem of physical springs, ensuring consistency in the processes of different batches of products.

[0019] 4. This invention utilizes a wire-laying compensation module and an online resistance prediction function to achieve real-time closed-loop control of finished product quality. On the one hand, the pitch of the wire-laying mechanism is adjusted in real time according to the changes in the measured diameter of the wire, ensuring that the wire maintains a dense wire-laying density even under tensile stress, thus avoiding the risk of local overheating. On the other hand, by recording the historical curve of the strain state throughout the entire process, the predicted resistance value after winding is calculated online through integration, realizing detection upon winding. This mechanism enables the equipment to immediately detect deviations and perform quality control during the production process, effectively solving the problem of low yield caused by uneven wire density and excessive resistance in traditional methods. Attached Figure Description

[0020] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0021] Figure 1This is a flowchart of the method of the present invention. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0023] Example 1:

[0024] A precision winding device for multi-specification heating wires includes: a spindle winding unit for driving the winding skeleton to rotate; an active wire feeding unit for feeding wire to the spindle winding unit; a micro-deformation monitoring unit disposed between the spindle winding unit and the active wire feeding unit, and for collecting the radial dimension data of the wire in real time; and a controller electrically connected to the spindle winding unit, the active wire feeding unit, and the micro-deformation monitoring unit respectively. The controller is equipped with a material rheology model. Based on the geometric parameters of the winding skeleton and the material rheology model, the controller generates feedforward control commands for the active wire feeding unit. During the operation of the spindle winding unit, based on the radial dimension data fed back by the micro-deformation monitoring unit, the controller calculates the real-time strain state of the wire. When the real-time strain state exceeds a preset elastic deformation threshold, a compensation torque command is superimposed and sent to the active wire feeding unit.

[0025] This embodiment details the physical architecture based on strain gradient feedforward compensation. The spindle winding unit, as the kinetic energy core of the system, is directly driven by a high-precision servo motor to rotate the winding frame, such as a mica sheet or ceramic tube. Its position feedback resolution is set to be better than 23 bits to ensure the microscopic controllability of the rotation angle. The active wire feeding unit is configured to cooperate with the spindle to establish a controlled tension field. This unit uses a servo motor-driven wire feeding wheel assembly and has bidirectional adjustment capabilities for active acceleration and deceleration to respond to millisecond-level speed change commands. The micro-deformation monitoring unit is arranged in the free line segment region between the spindle and the wire feeding unit. Its real-time acquired radial dimension data is not only used to monitor fracture, but more importantly, to capture the necking effect of the wire under stress. Based on this, the core controller performs calculations using the internally configured material rheology model.

[0026] Material rheology model: It is derived from a pre-set mathematical model. Its physical meaning is an algorithm that describes the nonlinear relationship between stress, strain and time in the dynamic stress process of the heating wire. It aims to predict the viscoelastic and plastic behavior of the wire at a specific tensile speed.

[0027] The controller performs feedforward calculations based on the geometric parameters of the winding skeleton, such as aspect ratio, chamfer radius, and the aforementioned model, to generate feedforward control commands for the active wire feeding unit. This allows the system to obtain a wire feeding speed fluctuation curve that adapts to the skeleton shape before winding begins. During operation, the controller calculates the real-time strain state of the wire based on the radial dimension data. If the real-time strain state exceeds the preset elastic deformation threshold, the controller determines that the wire is about to enter the irreversible plastic deformation zone and immediately sends a compensation torque command to the active wire feeding unit, instantly reducing the wire feeding resistance.

[0028] Example 2:

[0029] The controller includes a dynamic fingerprint library module, which stores constitutive equation parameters for wires of different specifications. The controller receives the target resistance value and material constant of the wire from the external input, and calls the corresponding yield strength threshold from the dynamic fingerprint library module as the elastic deformation threshold. The controller sets the maximum allowable radial shrinkage rate of the wire during the winding process based on the target resistance value and material constant.

[0030] This embodiment further defines the controller's initialization configuration and parameter mapping mechanism; the system initializes the dynamic fingerprint library module, which serves as a multi-dimensional database inside the controller and stores constitutive equation parameters covering different specifications, such as wire diameters of 0.1mm-0.8mm, and different materials, such as Cr20Ni80 and 0Cr25Al5 wires.

[0031] Constitutive equation parameters: sourced from the dynamic fingerprint library module, and physically meaningd as key physical quantities describing the mechanical properties of materials, specifically including Young's modulus E, Poisson's ratio ν, and yield strength σy;

[0032] The controller receives the target resistance value and the material constant of the wire from external input. Based on these inputs, it automatically retrieves the corresponding yield strength threshold from the dynamic fingerprint library module and maps it to the elastic deformation threshold. The controller then performs calculations to set the maximum allowable radial shrinkage rate. The calculation logic is as follows:

[0033]

[0034] in, The value is derived from controller calculations and its physical meaning is the maximum permissible radial shrinkage rate, expressed in % (%).

[0035] u: The source is the dynamic fingerprint library module, and its physical meaning is the Poisson's ratio of the wire, which is dimensionless;

[0036] The source is the dynamic fingerprint database module, and its physical meaning is yield strength, with the unit being MPa.

[0037] The source is the dynamic fingerprint database module, and its physical meaning is Young's modulus, with the unit being MPa;

[0038] This calculation process ensures that the control boundary is adapted to the physical limits of the current material;

[0039] This embodiment achieves an intelligent leap in production changeover by introducing a dynamic fingerprint database and an automatic parameter mapping mechanism. The system no longer relies on operators to repeatedly adjust the mechanical tension springs, but automatically generates control boundaries that adapt to physical limits based on the target resistance and material. This data-driven parameter configuration method significantly reduces changeover time from hours to seconds, greatly improving equipment utilization and process consistency in multi-variety, small-batch production scenarios.

[0040] Example 3:

[0041] The controller includes an electronic cam calculation module; the electronic cam calculation module constructs a nonlinear mapping relationship between the rotation angle and linear velocity of the main spindle winding unit based on the cross-sectional shape data of the winding skeleton, and generates a velocity fluctuation curve; the controller uses the inverse operator of the constitutive equation to calculate the reverse acceleration required to counteract the tension fluctuation based on the velocity fluctuation curve, and converts the reverse acceleration into a feedforward control command to be sent to the active wire feeding unit.

[0042] This embodiment describes in detail the electronic cam calculation module and its feedforward control strategy for a non-circular skeleton. The electronic cam calculation module receives the cross-sectional shape data of the winding skeleton, such as the major axis L and the minor axis S, and constructs the rotation angle of the main shaft winding unit based on this data. With wire winding linear speed The nonlinear mapping relationship between them is used to generate the velocity fluctuation curve; the controller uses the inverse constitutive equation operator to perform reverse acceleration calculation, which aims to calculate the motion compensation amount required to maintain constant deformation of the wire feed shaft; in order to solve the dimension matching problem of angular acceleration and linear velocity, the radius of the wire feed wheel is introduced as a conversion factor, and the specific modified calculation formula is as follows:

[0043]

[0044] in, The source is the controller's calculated output; its physical meaning is the feedforward and reverse angular acceleration of the active wire feeding unit, and its unit is... ;

[0045] The source is system parameters, and its physical meaning is the effective radius of the active wire feed wheel, in mm;

[0046] The source is the real-time feedback from the spindle encoder; its physical meaning is the current angular velocity of the spindle, measured in units of... ;

[0047] The source is an electronic cam curve constructed from skeleton geometry data; its physical meaning is the angle of the skeleton. The instantaneous winding radius at the point, in mm;

[0048] The source is the preset process parameters, and the physical meaning is the target tensile stress, with the unit being MPa;

[0049] The source is a dynamic fingerprint database call; the physical meaning is the cross-sectional area of ​​the wire, in units of... ;

[0050] The source is the system calibration value; its physical meaning is the equivalent moment of inertia of the wire feeding system, and the unit is... ;

[0051] The controller will calculate It is converted into feedforward control commands to directly drive the active wire feeding unit;

[0052] This embodiment achieves proactive management of non-circular winding line speed pulsation through a reverse calculation strategy based on a geometric model. The system controls the wire feeding motor to pre-accelerate or pre-decelerate before physical tension fluctuations occur, effectively offsetting the periodic impact generated when the flat skeleton rotates. This ensures that the internal stress of the wire remains stable even under extreme conditions of high-speed winding of non-circular cross-section skeletons, thus solving the problem of tension oscillation in non-standard skeleton winding.

[0053] Example 4:

[0054] The micro-deformation monitoring unit is a laser diffraction diameter gauge, which measures the diameter change of the wire using the principle of laser diffraction at a preset sampling frequency. The controller includes a strain analysis module, which receives radial dimension data and calculates the current radial shrinkage rate of the wire. When the current radial shrinkage rate is greater than the shrinkage rate limit corresponding to the elastic deformation threshold, the controller determines that the wire has entered the plastic deformation zone and generates a compensation torque command to reduce the output impedance of the active wire feeding unit. When the current radial shrinkage rate is less than or equal to the shrinkage rate limit, the controller maintains the current control state of the active wire feeding unit.

[0055] This embodiment details the hardware selection of the micro-deformation monitoring unit and the closed-loop control logic of the strain analysis module. The micro-deformation monitoring unit uses a laser diffraction diameter gauge, installed between the output end of the active wire feeding unit and the input end of the spindle. Its sampling frequency is set to at least 2kHz to capture microscopic defects in high-speed winding. The strain analysis module receives radial dimension data fed back from the laser diffraction diameter gauge. And calculate the current radial shrinkage rate according to the formula. :

[0056]

[0057] in, The data is from real-time calculations, and its physical meaning is the current radial contraction rate, expressed in % (%).

[0058] The source is a system setting, and the physical meaning is the nominal diameter of the wire, in mm;

[0059] The source is a laser diffraction diameter gauge; its physical meaning is the measured diameter, and the unit is mm.

[0060] The system executes dual-modal control logic to determine: in response to If the shrinkage rate exceeds the elastic deformation threshold, the controller determines that the wire has entered the plastic deformation zone and generates a compensation torque command to reduce the output impedance of the active wire feeding unit, instantly reducing the reverse torque of the wire feeding motor to release stress concentration; in response to If the shrinkage rate is less than or equal to the shrinkage limit, the controller determines that the wire is within a safe range of elastic deformation and maintains the current control state of the active wire feeding unit, that is, only performs feedforward control.

[0061] This embodiment constructs a safety airbag-like protection mechanism; under normal conditions, the system relies solely on a high-precision feedforward model to ensure response speed, and only intervenes with feedback when the wire is about to be thinned. This layered control strategy not only ensures dynamic response performance, but also eliminates resistance values ​​exceeding tolerances due to wire hard spots or knots, achieving the process goal of zero scrap in high-speed precision winding scenarios.

[0062] Example 5:

[0063] The controller includes a wiring compensation module; the wiring compensation module is connected in communication with the micro-deformation monitoring unit and adjusts the wiring pitch of the wiring mechanism in real time according to the changes in radial dimension data to match the actual diameter of the wire under stress.

[0064] This embodiment describes the details of the linkage control of the wire winding mechanism; the wire winding compensation module establishes a real-time communication connection with the micro-deformation monitoring unit; during the winding process, considering that the diameter of the wire will change slightly due to the tensile force, winding according to the nominal diameter may lead to gaps or overlaps. Therefore, this module calculates the radial dimension data... The changes in the cable laying mechanism are adjusted in real time to control the cable laying pitch. The calculation logic is as follows:

[0065]

[0066] in, The source is the controller calculation, and its physical meaning is the cable pitch at time t, in mm;

[0067] The source is the process setting, and its physical meaning is the preset filling coefficient, which is usually 1.0-1.05;

[0068] The source is the micro-deformation monitoring unit, and its physical meaning is the measured diameter of the wire at time t, in mm;

[0069] The system drives the cable laying mechanism to adjust its displacement speed in real time based on the calculation results;

[0070] This embodiment ensures consistent density of the winding under dynamic stretching by using dynamic wiring compensation based on the measured diameter. This technique effectively avoids uneven wiring density caused by slight changes in wire diameter, ensuring uniform heat conduction for the heating wire assembly and thus avoiding the risk of burnout due to local overheating.

[0071] Example 6:

[0072] Both the active wire feeding unit and the spindle winding unit are driven by servo motors; the controller controls the active wire feeding unit and the spindle winding unit through a bus synchronization mechanism to establish a bidirectional active micro-differential motion relationship; the active wire feeding unit is configured as a simulated virtual spring damping system, and the stiffness coefficient of the virtual spring damping system is dynamically adjusted in real time by the controller according to the specifications of the wire.

[0073] This embodiment illustrates the implementation of a dual-motor cooperative drive architecture and a virtual spring damping system; both the active wire feeding unit and the spindle winding unit are driven by servo motors and synchronized at the microsecond level via an EtherCAT bus; the controller establishes a bidirectional active micro-differential speed relationship between the two, enabling the wire feeding speed to... Slightly less than the winding speed Tension is generated by utilizing the speed difference; the active wire feeding unit is configured to simulate a virtual spring-damped system that does not exist physically, and its control equations are as follows:

[0074]

[0075] in, The source is the controller calculation; its physical meaning is the output torque command of the wire-feeding motor; the unit is... ;

[0076] The source is dynamically adjusted in real time according to wire specifications; its physical meaning is the virtual stiffness coefficient, and the unit is... ;

[0077] The source is a system setting; its physical meaning is the virtual damping coefficient; the unit is... ;

[0078] During this process, the controller adjusts the parameters according to the wire specifications, such as cross-sectional area. Young's modulus Real-time dynamic adjustment The specific mapping function is defined as follows:

[0079]

[0080] in, The source is the adjustment correction coefficient, with a value range of 0.8-1.2, used to compensate for the flexibility of the transmission chain;

[0081] The source is a dynamic fingerprint database, and the physical meaning is the Young's modulus of the wire, with the unit being MPa;

[0082] The source is the wire specification; its physical meaning is cross-sectional area; the unit is... ;

[0083] The source is the mechanical structure constant, and its physical meaning is the length of the free line segment between the feed wheel and the winding point, with the unit being mm;

[0084] This formula ensures that the system automatically increases the voltage for thick or hard wires. To provide a matching high tension, automatically reducing for thinner threads. To improve flexibility;

[0085] This embodiment uses software algorithms to endow a rigid motor with flexible characteristics; compared with physical springs, the parameters of virtual springs can be adjusted online steplessly, and the inherent resonance frequency and fatigue failure problems of physical springs are completely eliminated, perfectly adapting to the flexible production needs of multi-specification wires, and realizing the digital reconstruction of the tension control system.

[0086] Example 7:

[0087] The device also includes: a memory, electrically connected to the controller, for recording radial dimension data and historical curves of real-time strain status during the winding process; the controller calculates the predicted resistance value after winding is completed online based on the historical curves and the elastic elongation of the wire, and performs the winding-and-detection function.

[0088] This embodiment describes a data-driven quality traceability and online prediction function; the memory continuously records radial dimension data and real-time strain status throughout the winding process, forming a process fingerprint of the product; the controller executes a winding-and-detection function, calculating the predicted resistance value after winding is completed online based on historical curves and the elastic elongation of the wire. The calculation principle is based on the integral form of the resistance law:

[0089]

[0090] in, The source is controller calculation; its physical meaning is predicted resistance value; the unit is... ;

[0091] The source is the material constant, its physical meaning is resistivity, and the unit is... ;

[0092] The source is the radial shrinkage rate. The physical meaning of Poisson's ratio is the axial elongation at position l, which is obtained by conversion.

[0093] The source is the specification parameters, and the physical meaning is the initial cross-sectional area of ​​the wire.

[0094] The system ultimately outputs this predicted value for quality assessment;

[0095] This embodiment realizes the concept of quality control in advance; the system does not need to perform additional resistance measurement after the winding is completed. Instead, it obtains the final resistance prediction value immediately during the production process through real-time integration calculation. This online prediction mechanism enables the system to make timely fine-tuning compensation or mark defective products when it deviates from the target, which greatly reduces the back-end inspection cost and quality loss.

[0096] Example 8:

[0097] Please see Figure 1A control method for a precision winding device for multi-specification heating wires includes the following steps: constructing a stress-strain constitutive model of the wire and setting a maximum allowable radial shrinkage rate threshold according to the wire specifications; generating a nonlinear mapping relationship between the spindle rotation angle and linear velocity based on the geometry of the winding skeleton, and calculating the feedforward reverse acceleration of the active wire feeding unit accordingly; driving the active wire feeding unit to operate according to the feedforward reverse acceleration to counteract tension fluctuations caused by the geometry; detecting the radial dimension change of the wire in real time through a micro-deformation monitoring unit and calculating the real-time radial shrinkage rate; and comparing the real-time radial shrinkage rate with the maximum allowable radial shrinkage rate threshold. When the real-time radial shrinkage rate exceeds the maximum allowable radial shrinkage rate threshold, the output of the active wire feeding unit is corrected by superimposing a compensation torque. When the real-time radial shrinkage rate does not exceed the maximum allowable radial shrinkage rate threshold, the current feedforward control output is maintained.

[0098] In the step of driving the active wire feeding unit, a virtual impedance control strategy is adopted; the controller adjusts the stiffness parameters of the virtual impedance model in real time according to the Young's modulus of the wire; when a hard point or knot is detected in the wire causing a sudden change in the real-time radial shrinkage rate, the damping value of the virtual impedance model is instantly reduced to release stress concentration.

[0099] This embodiment details the execution flow and hard-point release mechanism of the control method. The system executes model construction and threshold setting steps, constructing a stress-strain constitutive model of the wire and setting the maximum allowable radial shrinkage rate threshold based on the wire specifications in the production order. The system performs nonlinear mapping and feedforward calculations, generating a nonlinear mapping relationship between the spindle rotation angle and linear velocity based on the geometry of the winding skeleton, and calculating the feedforward reverse acceleration of the active wire feeding unit accordingly. This acceleration aims to accelerate the wire feeding wheel in advance when the long axis of the skeleton rotates to the vertical position and decelerate it in advance when it reaches the short axis position. The system drives the active wire feeding unit and employs a virtual impedance control strategy. During this process, the controller adjusts the stiffness parameters of the virtual impedance model in real time based on the Young's modulus of the wire. Simultaneously, the system executes hard-point release logic. In response to the detection of hard points or knots in the wire causing sudden changes in the real-time radial shrinkage rate, such as a surge in shrinkage rate within 1 ms, the controller determines this as abnormal stress concentration and instantly reduces the damping value of the virtual impedance model. This causes the wire feeding motor to be instantly unloaded; the system performs micro-deformation closed-loop correction, continuously comparing the real-time radial shrinkage rate with the threshold. If the threshold is exceeded, a compensation torque is superimposed to force the wire to return to the elastic range; if the threshold is not exceeded, the current feedforward control output is maintained.

[0100] This embodiment addresses the limitations of traditional methods in handling wire defects through a control strategy that combines rigidity and flexibility. Feedforward control provides a rigid foundation for system operation, virtual impedance gives the system flexibility to adapt to changes, and the hard-point release mechanism provides instantaneous response capability to sudden defects. The three work together to provide a dynamic buffer at the knot, effectively preventing wire breakage caused by local defects during high-speed winding and ensuring the continuous stability of the production process.

[0101] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A precision winding device for multi-specification heating wires, characterized in that, include: The spindle winding unit is used to drive the winding skeleton to rotate. An active wire feeding unit is used to feed wire to the spindle winding unit; A micro-deformation monitoring unit is installed between the spindle winding unit and the active wire feeding unit, and collects the radial dimension data of the wire in real time. The system includes a controller, which is electrically connected to the spindle winding unit, the active wire feeding unit, and the micro-deformation monitoring unit, respectively. The controller is equipped with a material rheology model. Based on the geometric parameters of the winding skeleton and the material rheology model, the controller generates feedforward control commands for the active wire feeding unit. During the operation of the spindle winding unit, the controller calculates the real-time strain state of the wire based on the radial dimension data fed back by the micro-deformation monitoring unit. When the real-time strain state exceeds a preset elastic deformation threshold, the controller sends a compensation torque command to the active wire feeding unit.

2. The multi-specification heating wire precision winding device according to claim 1, characterized in that, The controller includes a dynamic fingerprint library module, which stores constitutive equation parameters for wires of different specifications; the controller receives the target resistance value and the material constant of the wire from an external input, and retrieves the corresponding yield strength threshold from the dynamic fingerprint library module as the elastic deformation threshold; the controller sets the maximum allowable radial shrinkage rate of the wire during the winding process based on the target resistance value and the material constant.

3. The multi-specification heating wire precision winding device according to claim 1, characterized in that, The controller includes an electronic cam calculation module; the electronic cam calculation module constructs a nonlinear mapping relationship between the rotation angle and linear velocity of the spindle winding unit based on the cross-sectional shape data of the winding skeleton, and generates a velocity fluctuation curve; the controller uses the inverse constitutive equation operator to calculate the reverse acceleration required to counteract tension fluctuations based on the velocity fluctuation curve, and converts the reverse acceleration into the feedforward control command and sends it to the active wire feeding unit.

4. The multi-specification heating wire precision winding device according to claim 1, characterized in that, The micro-deformation monitoring unit is a laser diffraction diameter gauge, which measures the diameter change of the wire using the principle of laser diffraction at a preset sampling frequency. The controller includes a strain analysis module, which receives the radial dimension data and calculates the current radial shrinkage rate of the wire. When the current radial shrinkage rate is greater than the shrinkage rate limit corresponding to the elastic deformation threshold, the controller determines that the wire has entered the plastic deformation zone and generates the compensation torque command to reduce the output impedance of the active wire feeding unit. When the current radial shrinkage rate is less than or equal to the shrinkage rate limit, the controller maintains the current control state of the active wire feeding unit.

5. The multi-specification heating wire precision winding device according to claim 4, characterized in that, The controller includes a wiring compensation module; the wiring compensation module is communicatively connected to the micro-deformation monitoring unit and adjusts the wiring pitch of the wiring mechanism in real time according to the changes in the radial dimension data to match the actual diameter of the wire under stress.

6. The multi-specification heating wire precision winding device according to claim 1, characterized in that, Both the active wire feeding unit and the spindle winding unit are driven by servo motors; the controller controls the active wire feeding unit and the spindle winding unit through a bus synchronization mechanism to establish a bidirectional active micro-differential motion relationship; the active wire feeding unit is configured as a simulated virtual spring damping system, and the stiffness coefficient of the virtual spring damping system is dynamically adjusted in real time by the controller according to the specifications of the wire.

7. The multi-specification heating wire precision winding device according to claim 1, characterized in that, The device further includes: a memory, electrically connected to the controller, for recording the radial dimension data and the historical curve of the real-time strain state during the winding process; the controller calculates the predicted resistance value after winding is completed online based on the historical curve and the elastic elongation of the wire, and performs the winding-detection function.

8. A control method for a multi-specification heating wire precision winding device, based on the multi-specification heating wire precision winding device as described in claim 1, characterized in that, Includes the following steps: Construct a stress-strain constitutive model for the wire and set a maximum permissible radial shrinkage threshold based on the wire specifications; Based on the geometry of the wound skeleton, a nonlinear mapping relationship between the spindle rotation angle and the linear velocity is generated, and the feedforward reverse acceleration of the active wire feeding unit is calculated accordingly. The active wire feeding unit is driven to operate according to the feedforward reverse acceleration to counteract tension fluctuations caused by geometry; the radial dimension change of the wire is detected in real time by the micro-deformation monitoring unit, and the real-time radial shrinkage rate is calculated; the real-time radial shrinkage rate is compared with the maximum allowable radial shrinkage rate threshold; when the real-time radial shrinkage rate exceeds the maximum allowable radial shrinkage rate threshold, the output of the active wire feeding unit is corrected by superimposing a compensation torque; when the real-time radial shrinkage rate does not exceed the maximum allowable radial shrinkage rate threshold, the current feedforward control output is maintained.

9. The control method for a multi-specification heating wire precision winding device according to claim 8, characterized in that, In the step of driving the active wire feeding unit, a virtual impedance control strategy is adopted; the controller adjusts the stiffness parameters of the virtual impedance model in real time according to the Young's modulus of the wire; when a hard point or knot is detected in the wire causing a sudden change in the real-time radial shrinkage rate, the damping value of the virtual impedance model is instantly reduced to release stress concentration.

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