Rim steel wire rubber coating control method and system, and electronic device

Abstract

The application provides a steel ring steel wire rubber coating control method and system and an electronic device, which are applied to a steel ring winding production line, the production line comprises a winding machine and an extruder, and the method comprises the following steps: acquiring a real-time winding speed of the winding machine and a real-time running current of the extruder; calculating a reference rotating speed of the extruder according to the real-time winding speed and a preset coordination coefficient; determining a corresponding target current according to the real-time winding speed, calculating a current deviation between the target current and the real-time running current, generating a rotating speed compensation amount based on the current deviation through a closed-loop controller; and determining a target rotating speed of the extruder according to the reference rotating speed and the rotating speed compensation amount, so that the extruder is controlled to run at the target rotating speed. The real-time optimization control of the target rotating speed of the extruder is realized, the rubber coating quality problems, such as insufficient rubber in the acceleration stage and rubber accumulation in the deceleration stage, caused by the rubber supply response lag in the traditional mode are solved, the accurate matching between the rubber supply amount and the steel wire consumption amount is realized, and the production efficiency and stability are improved.

Description

Technical Field

[0001] This invention relates to the field of adhesive application control technology for steel rings and wires, specifically to a method, system, and electronic device for adhesive application control of steel rings and wires. Background Technology

[0002] The steel rim is a key structural component of a tire, and its quality directly affects the tire's load-bearing capacity, safety, and lifespan. In the steel rim production process, steel wire winding and adhesive application is a core step. This involves a winding machine winding steel wires into a loop according to a preset trajectory, while an extruder evenly coats the steel wire surface with adhesive during the winding process, forming an adhesive-coated steel wire loop with good adhesion and cushioning properties. Currently, traditional steel rim wire adhesive application production lines typically use an independent control mode, where the winding machine and extruder operate independently according to preset parameters, with only a simple start-stop relationship and a lack of deep dynamic collaborative control. Specifically, operators pre-set the winding speed and extruder speed according to production specifications. After the equipment starts, the winding machine begins to pull the steel wires, and the extruder starts synchronously or with a delay to supply adhesive. During production, when adjustments to the production speed are needed, or when changing layers or reels, operators manually adjust the extruder speed to match the changes in winding speed by visually assessing the adhesive application effect.

[0003] However, the aforementioned traditional solutions have certain drawbacks in practical applications. On the one hand, due to the distance between the extruder die and the wire winding point, the rubber compound needs a certain amount of time to be conveyed from the die to the winding point when the equipment starts. If the winding machine and the extruder start simultaneously, or the winding machine starts before the extruder, the steel wire may have already moved but the rubber compound may not have arrived, resulting in a situation where the initial section of the steel wire is not wrapped with rubber compound or is not wrapped sufficiently within a length of several meters or even tens of meters. This portion of the product can only be treated as scrap, leading to a waste of raw materials. During the steel ring winding process, the winding speed is not constant but fluctuates due to changes in production process requirements or equipment operating conditions. The instantaneous consumption of steel wire also changes accordingly. However, there is an inherent physical lag in adjusting the rubber supply of the extruder. After the screw speed is adjusted, the extrusion pressure and flow rate of the rubber compound need a certain amount of time to stabilize. When the winding speed increases, wire consumption accelerates, but the extruder's glue supply fails to increase simultaneously, resulting in a thinner glue layer or exposed wire on the wire surface. Conversely, when the winding speed decreases, wire consumption slows down, but the extruder's glue supply fails to decrease in time, causing glue to accumulate on the wire surface, forming lumps or dimensional errors, affecting subsequent molding processes. Traditional solutions to address these speed fluctuations rely heavily on operator experience for manual intervention. Operators observe the surface condition of the glued wire or listen to the motor's sound to judge load changes, then manually adjust the extruder speed knob. This manual adjustment method is slow to respond and lacks precise quantitative control, leading to large fluctuations in the scrap rate.

[0004] In summary, the existing technology lacks a quality control solution for steel wire coating of steel rings that can fundamentally solve problems such as start-up defects, lag in dynamic response, and high dependence on manual labor. This results in significant material waste, poor product consistency, and limited production efficiency during the steel ring production process.

[0005] Therefore, the existing technology still needs further development. Summary of the Invention

[0006] The purpose of this invention is to overcome the above-mentioned technical deficiencies and provide a method, system, and electronic device for controlling the application of adhesive to steel wires in steel rings, so as to solve the problems existing in the prior art.

[0007] To achieve the above-mentioned technical objectives, according to a first aspect of the present invention, a method for controlling the adhesive application of steel wire in steel rings is provided, applied to a steel ring winding production line, the production line including a winding machine and an extruder, the method comprising: S100: Obtain the real-time winding speed of the winding machine and the real-time operating current of the extruder; S200. Calculate the reference rotational speed of the extruder based on the real-time winding speed and the preset coordination coefficient; S300. Determine the corresponding target current based on the real-time winding speed, calculate the current deviation between the target current and the real-time operating current, and generate a speed compensation amount through a closed-loop controller based on the current deviation. S400. Based on the reference speed and the speed compensation amount, determine the target speed of the extruder so as to control the extruder to operate at the target speed.

[0008] Specifically, the closed-loop controller is a PID controller, and the generation of speed compensation based on the current deviation through the closed-loop controller includes: The speed compensation amount is generated by performing proportional, integral, and derivative operations on the current deviation using a PID control algorithm.

[0009] Specifically, the method further includes: Upon receiving the start command, the extruder is started first. Obtain a rubber material arrival signal, which indicates that the rubber material output from the extruder die has reached the wire winding point; In response to the rubber material arrival signal, the winding machine is started.

[0010] Specifically, the preset coordination coefficient is obtained through experimental calibration, and the coordination coefficient is used to establish a linear mapping relationship between the real-time winding speed of the winding machine and the reference speed of the extruder.

[0011] Specifically, determining the corresponding target current based on the real-time winding speed includes: Based on the preset relationship between winding speed and extruder operating current, determine the target current corresponding to the real-time winding speed; The relationship between the preset winding speed and the extruder operating current is obtained through experimental calibration and is used to represent the extruder operating current corresponding to the glue application quality meeting the preset standard under different winding speeds.

[0012] Specifically, the method for determining the target speed of the extruder based on the reference speed and the speed compensation amount includes: The target speed of the extruder is obtained by superimposing the reference speed and the speed compensation amount.

[0013] Specifically, the method further includes: The proportional coefficient, integral coefficient, and derivative coefficient in the PID control algorithm are pre-tuned so that the real-time operating current of the extruder can track the target current during the real-time winding speed change of the winding machine, and the current adjustment during the tracking process is within a first preset threshold range.

[0014] According to a second aspect of the present invention, a steel wire adhesive application control system for steel rings is provided, comprising: Acquisition module: used to acquire the real-time winding speed of the winding machine and the real-time operating current of the extruder; Calculation module: used to calculate the reference speed of the extruder based on the real-time winding speed and the preset coordination coefficient; determine the corresponding target current based on the real-time winding speed; calculate the current deviation between the target current and the real-time operating current; and generate a speed compensation amount through a closed-loop controller based on the current deviation. Control module: used to determine the target speed of the extruder based on the reference speed and the speed compensation amount, so as to control the extruder to operate at the target speed.

[0015] Specifically, the control module is a PID controller, which is used to perform proportional, integral and derivative operations on the current deviation through a PID control algorithm to generate the speed compensation amount.

[0016] According to a third aspect of the present invention, an electronic device is provided, comprising: a memory; and a processor, wherein the memory stores computer-readable instructions, which, when executed by the processor, implement the above-described method for controlling the application of adhesive to steel wire and steel ring.

[0017] Beneficial effects: This invention provides a method and system for controlling the application of adhesive to steel wire in steel coils. By using the real-time winding speed of the winding machine as the master signal, and combining it with a preset coordination coefficient to calculate the extruder's reference speed, a rapid feedforward response to the adhesive supply is achieved. Simultaneously, the real-time operating current of the extruder is introduced as a feedback parameter characterizing the actual load state. A closed-loop controller dynamically corrects the current deviation to generate speed compensation, thereby precisely fine-tuning the reference speed. This achieves real-time optimized control of the extruder's target speed, solving adhesive application quality problems caused by delayed adhesive supply response in traditional control methods, such as exposed wire at startup, insufficient adhesive during acceleration, and adhesive accumulation during deceleration. It achieves dynamic and precise matching between adhesive supply and steel wire consumption, significantly improving the uniformity and consistency of the adhesive thickness, greatly reducing the scrap rate. Furthermore, it transforms the adjustment process, which relies on manual experience, into fully automated intelligent control, greatly improving product production efficiency and stability. Attached Figure Description

[0018] Figure 1 This is a flowchart of the method for controlling the adhesive application of steel rings and steel wires according to a specific embodiment of the present invention; Figure 2 This is a schematic diagram of the system composition of the steel ring and steel wire adhesive application control system provided in a specific embodiment of the present invention. Detailed Implementation

[0019] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Based on the embodiments in this application, other similar embodiments obtained by those skilled in the art without creative effort should all fall within the scope of protection of this application. Furthermore, directional terms mentioned in the following embodiments, such as "up," "down," "left," and "right," are only for reference to the directions in the accompanying drawings; therefore, the directional terms used are for illustrative purposes and not for limiting the invention.

[0020] The present invention will be further described below with reference to the accompanying drawings and preferred embodiments.

[0021] Example 1 Please see Figure 1This embodiment provides a method for controlling the adhesive application of steel wire in steel rings, applied to a steel ring winding production line. The production line includes a winding machine and an extruder. The method includes: acquiring the real-time winding speed of the winding machine and the real-time operating current of the extruder; calculating the reference speed of the extruder based on the real-time winding speed and a preset coordination coefficient; determining the corresponding target current based on the real-time winding speed, calculating the current deviation between the target current and the real-time operating current, and generating a speed compensation amount through a closed-loop controller based on the current deviation; and determining the target speed of the extruder based on the reference speed and the speed compensation amount, so as to control the extruder to operate at the target speed.

[0022] Understandably, the above technical solution uses the real-time winding speed of the winding machine as the master signal and combines it with a preset coordination coefficient to calculate the extruder's reference speed, thereby achieving a rapid feedforward response to the extruder's glue supply and ensuring that the extruder can make corresponding speed adjustments as soon as the winding speed changes. At the same time, the real-time operating current of the extruder is introduced as a feedback parameter characterizing the actual load state and glue output. The current deviation is dynamically corrected by a closed-loop controller to generate a speed compensation amount, thereby precisely fine-tuning the reference speed. This achieves a dual coordination mechanism of feedforward prediction and feedback compensation. The feedforward part ensures a rapid response to speed changes, while the feedback part overcomes the influence of interference factors such as glue viscosity fluctuations, temperature changes, and equipment wear on the glue supply accuracy. By adopting the above technical solution, the actual glue output of the extruder can be matched with the instantaneous consumption of the wire winding in real time and accurately. This solves the glue application quality problems caused by the lag in glue supply response under the traditional control method, such as exposed wire at the start, insufficient glue in the acceleration stage, and glue accumulation in the deceleration stage. It significantly improves the uniformity and consistency of glue application thickness, greatly reduces the scrap rate, and realizes the transformation from relying on manual experience to fully automatic intelligent control, effectively improving production efficiency and product stability.

[0023] See Figure 1 The specific implementation steps of the adhesive application control method for steel rings and steel wires in this embodiment are as follows: S100: Obtain the real-time winding speed of the winding machine and the real-time operating current of the extruder; It should be noted that in step S100, obtaining the real-time winding speed of the winding machine and the real-time operating current of the extruder is the data basis for the steel wire coating control of the steel ring in this embodiment. The real-time winding speed refers to the instantaneous linear velocity of the traction steel wire movement of the winding machine. It can be directly measured by installing a rotary encoder at the traction wheel or calculated by reading the rotational speed from the driver. This parameter serves as the master command signal of the control system and is used for feedforward calculation of the extruder's reference rotational speed. The real-time operating current refers to the instantaneous operating current of the extruder's main drive motor. It can be obtained through inverter communication or current sensor acquisition and is used to characterize the real-time load state of the extruder, i.e., the resistance of the rubber compound to the extruder screw. It is highly correlated with the extrusion pressure, rubber viscosity (affected by temperature), and actual rubber output. Its magnitude is positively correlated with the screw load torque and can comprehensively reflect multiple process information such as extrusion pressure, rubber viscosity, actual rubber output, and equipment status.

[0024] The two parameters mentioned above constitute a dual-input structure of master command plus feedback in the control logic. The real-time winding speed is used for feedforward response to ensure rapid follow-up to speed changes, while the real-time operating current is used for feedback correction to overcome the influence of interference factors such as rubber material characteristic fluctuations, temperature changes, and equipment wear on the rubber supply accuracy. By synchronously acquiring these two parameters, the control system can calculate the current deviation in real time and make dynamic corrections in each control cycle of the winding speed change, thereby achieving precise control of the extruder speed and ensuring instantaneous matching between the rubber supply and the wire consumption.

[0025] S200. Calculate the reference rotational speed of the extruder based on the real-time winding speed and the preset coordination coefficient; In this embodiment, the preset coordination coefficient is obtained through experimental calibration. The coordination coefficient is used to establish a linear mapping relationship between the real-time winding speed of the winding machine and the reference speed of the extruder.

[0026] It should be further explained that in step S200 above, calculating the extruder's reference speed based on the real-time winding speed and the preset coordination coefficient is the core step in realizing feedforward predictive control. The preset coordination coefficient C is a quantitative parameter obtained through experimental calibration, used to establish the real-time winding speed V of the winding machine. wind With extruder reference speed N base The linear mapping relationship between them is expressed mathematically as N. base =V wind ×C is a comprehensive integration of various process factors such as wire specifications, rubber layer thickness, rubber compound characteristics, and extruder structural parameters. It achieves dimensionality reduction of complex process conditions, allowing operators to quickly adapt to different production specifications by calibrating only one coefficient.

[0027] The calibration of the preset coordination coefficient is typically performed during equipment commissioning or initial production changeover: At at least three different constant winding speeds, the extruder speed is manually adjusted until the adhesive application quality meets the preset standard. The corresponding stable speed data points are recorded. By linearly fitting multiple sets of data, the slope of the resulting straight line is the preset coordination coefficient C. In actual production, this coefficient is multiplied by the real-time winding speed in each control cycle to quickly calculate the reference speed. When the winding speed changes, the control system immediately provides a reference speed that is theoretically close to the final stable value based on the C value, significantly shortening the system's initial response time. Simultaneously, since the reference speed is close to the actual requirements, the subsequent PID closed-loop controller only needs minor adjustments, reducing the adjustment range and oscillation risk. When changing the wire specifications or adhesive formulation, only recalibration of the C value is required to complete the production line adaptation without modifying the control logic, significantly improving production changeover efficiency.

[0028] S300. Determine the corresponding target current based on the real-time winding speed, calculate the current deviation between the target current and the real-time operating current, and generate a speed compensation amount through a closed-loop controller based on the current deviation. In this embodiment, the closed-loop controller is a PID controller, and the method for generating the speed compensation amount based on the current deviation through the closed-loop controller is as follows: The speed compensation amount is generated by performing proportional, integral, and derivative operations on the current deviation using a PID control algorithm.

[0029] Understandably, by employing PID closed-loop control, with the theoretical extruder current setpoint calculated based on the winding speed as the target and the actual measured extruder current as feedback, the PLC's PID algorithm can dynamically adjust the extruder screw speed. When the actual current is lower than the set value, indicating insufficient glue supply, the PLC commands the speed to increase; conversely, it commands the speed to decrease. Specifically, the control system will use the target current I determined by the real-time winding speed... target As a set value, the extruder operating current I is collected in real time. actual As a feedback value, the deviation e between the two is calculated. After the deviation is input to the PID controller, the proportional term (P) responds quickly to the current deviation, the integral term (I) eliminates the steady-state error of the accumulated deviation, and the derivative term (D) predicts the rate of change of deviation in advance to suppress overshoot. The three work together to generate the speed compensation amount ΔN. This compensation amount is superimposed on the reference speed in real time in each control cycle to form the final target speed command of the extruder, realizing the dynamic correction of the glue supply.

[0030] The aforementioned PID closed-loop control, together with the reference speed feedforward calculation in step S200, constitutes a dual regulation mechanism of feedforward prediction and feedback compensation. The feedforward part ensures that the extruder can obtain a reference speed close to a stable value as soon as the winding speed changes. The feedback part, through real-time processing of current deviation by PID, accurately compensates for the influence of interference factors such as rubber viscosity fluctuations, temperature changes, and equipment wear on the rubber supply accuracy. This ensures that the actual rubber output of the extruder can always accurately match the instantaneous consumption of steel wire, maintaining the uniformity and consistency of the rubber coating thickness throughout the entire process of acceleration, deceleration, and constant speed.

[0031] In this embodiment, the steel wire coating control further includes: pre-tuning the proportional coefficient, integral coefficient, and derivative coefficient in the PID control algorithm so that the real-time operating current of the extruder can track the target current during the real-time winding speed change of the winding machine, and the current adjustment amount during the tracking process is within a first preset threshold range.

[0032] It should be noted that pre-tuning the proportional, integral, and derivative coefficients in the PID control algorithm is a necessary step to ensure good dynamic response performance of the closed-loop control system. Due to the electromechanical inertia and viscoelastic hysteresis characteristics of the extruder and its driven rubber conveying system, improper PID parameter tuning will lead to problems such as slow response, excessive overshoot, or steady-state fluctuations. Therefore, it is essential to determine the specific values ​​of the proportional coefficient Kp, integral coefficient Ki, and derivative coefficient Kd through engineering tuning methods, such as empirical trial and error, step response modeling, or online self-tuning. This ensures that the control system can respond quickly during changes in winding speed, allowing the extruder's real-time operating current to track the target current in a timely manner, while also controlling the current adjustment during the tracking process within a preset threshold range.

[0033] Understandably, the current adjustment within the first preset threshold range serves as a quantitative constraint on the PID parameter tuning. On one hand, it ensures that the overshoot of the actual current exceeding the target current during dynamic processes does not exceed the preset range (e.g., 5%), preventing adhesive buildup due to excessive instantaneous glue supply. On the other hand, it ensures that the fluctuation range of the actual current around the target current after entering steady state does not exceed the preset range, guaranteeing the stability of the glue supply during the uniform speed phase. By pre-tuning the PID parameters to meet these requirements, precise and stable adjustment of the glue supply is achieved throughout the entire winding speed acceleration, deceleration, and uniform speed process, ensuring both rapid dynamic response and uniform adhesive application quality.

[0034] In this embodiment, determining the corresponding target current based on the real-time winding speed specifically includes: Based on the preset relationship between winding speed and extruder operating current, determine the target current corresponding to the real-time winding speed; The relationship between the preset winding speed and the extruder operating current is obtained through experimental calibration and is used to represent the extruder operating current corresponding to the glue application quality meeting the preset standard under different winding speeds.

[0035] It should be noted that the aforementioned preset relationship between the winding speed and the extruder operating current was obtained through experimental calibration. Specifically, during equipment debugging or production changeover, the winding machine was set to run at several different constant speeds, and the extruder speed was manually adjusted until the adhesive application quality met the preset standards (e.g., uniform adhesive layer thickness, no exposed lines, no accumulation, and dimensions within tolerance). At this point, the extruder operating current during stable operation was recorded as the target current at that winding speed. By collecting stable current values ​​corresponding to at least three different speed points, the relationship between the winding speed and the target current can be constructed. This relationship can be expressed as a lookup table or a mathematical formula obtained through linear fitting.

[0036] Understandably, this correspondence is pre-stored in the control system during engineering implementation. When the production line is actually running, the PLC quickly obtains the corresponding target current value in each control cycle based on the current real-time winding speed by interpolating from a table or substituting into a formula. This target current represents the ideal load state that enables the adhesive application quality to meet the qualified standard at the current speed. It serves as the setting benchmark for the subsequent PID controller to calculate the current deviation. By comparing the real-time operating current with this experimentally verified ideal value, it is possible to accurately determine whether the current adhesive supply is too high or too low, thereby generating a precise speed compensation amount to ensure dynamic matching between the adhesive supply and the wire consumption under any operating condition.

[0037] S400. Based on the reference speed and the speed compensation amount, determine the target speed of the extruder so as to control the extruder to operate at the target speed.

[0038] Specifically, the method for determining the target speed of the extruder includes: superimposing the reference speed with the speed compensation amount to obtain the target speed of the extruder.

[0039] It should be further explained that the calculation logic for determining the target speed of the extruder in this embodiment to control the extruder to operate at the target speed includes open-loop proportional calculation and closed-loop current fine-tuning. The specific implementation steps are as follows: Step 1: Calculation of open-loop ratio Under steady-state conditions, the volume of rubber extruded per unit time must be equal to the theoretical volume of rubber required for wire winding per unit time, which can be expressed as follows: N base = V wind ×C; Where, Nbase This indicates the reference speed of the extruder screw, in rpm, V wind The winding speed is expressed in m / min. C represents the preset coordination coefficient, which is a key parameter calibrated through experiments. This coefficient takes into account the wire diameter and arrangement (which determines the required rubber volume), the rubber formulation and density, the extruder screw geometry (pitch and diameter), and the target rubber layer thickness. For example, if the calibration result is that for every 1 m / min winding speed, the corresponding screw speed is 5 rpm, then C=5.

[0040] Step 2: Real-time compensation through closed-loop current fine-tuning Establish a current-velocity model and record different stable winding speeds V under standard operating conditions, i.e., specific rubber compound and temperature. wind The corresponding ideal extruder operating current I target This forms a speed-target current comparison table; Use PLC to read the current winding speed V wind By looking up a table or formula, we can obtain I at this time. target The PLC simultaneously reads the real-time current I of the extruder motor. actual ; The speed compensation amount ΔN is calculated using a PID controller. The specific calculation formula is as follows: ΔN = Kp×(I target - I actual ) + Ki ×∫(I target - I actual )dt + Kd ×(d(I target -I actual ) / dt); The final output speed N is obtained. final as follows: N final =N base +ΔN; Taking a real-world scenario where a winding machine suddenly accelerates as an example: Theoretically, the winding speed V wind Increase the extruder screw reference speed N base It will also increase proportionally, but due to the viscoelasticity of the rubber compound, the actual increase in the amount of rubber dispensed is delayed, resulting in the screw load remaining unchanged temporarily, thus causing I actual Lower than the new I target When the PID controller detects a negative deviation, i.e. (I target - I actual When the value is greater than 0, a positive speed compensation amount ΔN is immediately output. The extruder increases its speed proportionally and then increases the speed further, so that the actual current quickly catches up with the target current, thereby allowing the actual glue output to quickly match the acceleration of the steel wire.

[0041] Understandably, by adopting the above technical solutions, the lagging response of traditional pure open-loop control is transformed into a fast and accurate response of feedforward prediction plus feedback compensation. This can overcome the technical problems of thinning of the adhesive layer, exposed wire, and decreased adhesion when the winding machine accelerates, as the steel wire moves too fast and the adhesive material cannot keep up. It can also overcome the technical problems of adhesive accumulation and out-of-tolerance size of adhesive lumps when the winding machine decelerates, as the steel wire moves too slowly and the adhesive material is continuously supplied. This further improves production efficiency and reduces the scrap rate in the production process.

[0042] In some specific embodiments, the above-mentioned method for controlling the adhesive application of steel rings and wires further includes a startup step, as follows: Upon receiving the start command, the extruder is started first. Obtain a rubber material arrival signal, which indicates that the rubber material output from the extruder die has reached the wire winding point; In response to the rubber material arrival signal, the winding machine is started.

[0043] Understandably, by establishing the above-mentioned rubber-first start-up sequence—that is, starting the extruder and running it at low speed before starting the wire winding—it is ensured that the rubber material has filled the die head and reached the winding point. When a signal indicating that the rubber material has arrived is received, such as pressure or timing, the wire winding is then started. This fundamentally eliminates the possibility of exposed wire during startup, ensuring that the actual rubber output of the extruder can match the instantaneous consumption of the wire winding in real time and accurately. In other words, the wire winding of the rubber material can be guaranteed at startup, thereby improving the product qualification rate.

[0044] The working principle of this invention is illustrated below using a specific example of a steel rim for an all-steel truck tire: Wire arrangement: single wire wound, wire diameter is 1.5mm; Target adhesive layer: Total diameter after adhesive coating is 3.0 mm, and single-sided adhesive thickness is 0.75 mm; Rubber compound: Natural rubber formulation, density 1.15 g / cm³; Extruder: Cold feed extruder, screw lead 120mm; Step 1: Calculation of open-loop ratio (1) Calibrate the preset synergy coefficient C As shown in Table 1, baseline data were obtained through experiments under stable production conditions: Table 1. Benchmark data for obtaining excellent adhesive coating quality under different production conditions. Calculate the preset synergy coefficient C: C = N base / V wind = 100 / 20.0 = 5.0 (rpm·min / m); Therefore, C = 5.0 rpm·min / m, which means that for every 1 m / min increase in winding speed, the extruder base speed needs to be increased by 5 rpm; (2) Establish a current-velocity comparison table From the above data, the ideal current model (linear fit) can be obtained: I target = 75 + V wind × 0.667; A more precise lookup table is shown in Table 2: Table 2 Target current corresponding to different winding speeds Step 2: Production instance calculation, taking the accelerated process as an example. In the initial steady state, assume the production line has been running stably for 5 minutes under the following conditions: Current winding speed: V wind_current = 20.0 m / min; Current extruder speed: N current = 100.0 rpm; Current extruder current: I actual = 85.0A; Adhesive application quality: Good.

[0045] The following example illustrates a real-world scenario for MES command acceleration: The MES issues a new command to increase the winding speed to 28.0 m / min. The control timing is as follows: At time t=0s, the PLC receives a new speed command and obtains V. wind_new =28.0 m / min; (1) Calculation of open-loop ratio: N base = V wind_new ×C = 28.0×5.0 = 140.0 rpm; This is the theoretical reference speed, which is an increase of N compared to the current extruder speed. base -N current = 140.0 - 100.0 = 40.0 rpm. (2) Target current lookup table: Linear interpolation is used for interpolation calculation: when V wind = 28.0 m / min; I target = 91.7 + (28.0-25.0)×{(95.0-91.7) / (30.0-25.0)} = 91.7 + 3×0.66=93.7A; (3) Initial state: Current actual current: I actual (t=0) = 85.0 A; Current deviation: e=I target -I actual =93.7 - 85.0 = 8.7 A; At time t = 0.1s (the first control cycle), assume the PID parameters are already tuned as follows: With Kp=0.5, Ki=0.1, Kd=0.05, and control period Δt=0.1s, the PID calculation is as follows: Proportional term P: Kp × e = 0.5 × 8.7 = 4.35; Integral term I (initial): Ki×e×Δt=0.1×8.7×0.1=0.087; Differential term D: Since it is the first step, its rate of change is 0; Speed ​​compensation: ΔN = P + I + D = 4.35 + 0.087 + 0 = 4.437 ≈ 4.4 rpm; Final output speed: N final =N base +ΔN=140.0+4.4=144.4rpm; Finally, the winding machine starts accelerating from 20.0 m / min, for example, at an acceleration of 2 m / s²; the extruder speed command jumps from 100.0 rpm to 144.4 rpm. It should be noted that this is the command value, and the actual motor has a response time. At time t=0.2s (the lag phase of the rubber compound response), the winding speed of the winding machine has increased to approximately 20.2 m / min, and the extruder speed is accelerating, assuming it reaches 120 rpm. However, due to the viscoelasticity of the rubber compound, the actual extrusion pressure has not yet been fully established, resulting in a lag in the current response. The actual current I... actual =86.5A, only an increase of 1.5A, the PID calculation is as follows: New deviation: e=I targe -I actual =93.7 - 86.5 = 7.2A; Deviation change rate: (e 电流偏差 -e 新偏差 ) / t=(8.7-7.2) / 0.1=15A / s; Item P: Kp × e new deviation = 0.5 × 7.2 = 3.6; Item I: Integral summation, 0.087 + (0.1 × 7.2 × 0.1) = 0.087 + 0.072 = 0.159; Option D: 0.05 × (-15) = -0.75 (negative values ​​suppress overshoot); ΔN=3.6+0.159-0.75=3.009≈3.0rpm; New output speed: N final =140.0+3.0=143.0rpm, which is slightly lower than the previous cycle, mainly because the differential term has begun to be suppressed; When time t = 1.0 s (close to steady state), the winding speed of the winding machine approaches 28.0 m / min, and the extruder current gradually rises to the target value, with the actual current I... actual =93.0A, PID calculation is as follows: Deviation: e = 93.7 - 93.0 = 0.7A. The integral term has accumulated to a certain value, and ΔN becomes very small, for example, 0.5 rpm. Final stable state: N final =140.0+0.5=140.5rpm, the actual current stabilizes at around 93.7A.

[0046] Table 3 compares this scheme with the traditional current-free closed-loop method: Table 3 compares this solution with the traditional current-free closed-loop method at different operating time periods. As shown in Table 3 above, by adopting the above scheme, intelligent control with theoretical calculation as the benchmark and real-time feedback for precise fine-tuning is achieved, ensuring that the supply of rubber material can be matched with the consumption of steel wire in real time and accurately during any speed change.

[0047] Understandably, this solution eliminates poor glue application during the start-up phase by using a glue-first startup logic, directly improving the yield rate. Through current closed-loop control, it combats interference from glue viscosity fluctuations, temperature fluctuations, and equipment wear in real time, ensuring that the glue supply and consumption are always matched throughout the entire process of winding acceleration, deceleration, and uniform speed. This keeps the glue thickness fluctuation within ±5%, reducing reliance on manual operation and achieving stable production.

[0048] It should be noted that this embodiment provides a method for controlling the adhesive application of steel wire in steel rings. The steel wire winding speed is set as the master speed, and the extruder screw speed is used as the driven speed, establishing a real-time following relationship. Simultaneously, the extruder current is introduced as a key feedback, and the drive current of the extruder main motor is used as a core process parameter. This precisely defines the start-up sequence of the adhesive material, combining the actions of two independent devices. This solves the technical problem of uneven adhesive application in steel ring manufacturing, ensuring that the adhesive supply matches the steel wire winding consumption in real time at any speed change stage. This ensures that the steel wire is completely and evenly wrapped with adhesive from 360 degrees, avoiding uneven adhesive layer thickness caused by supply fluctuations, and greatly improving the structural uniformity and dimensional accuracy of the steel wire ring. It achieves controlled adhesive application quality from the start to the end of winding, including acceleration, deceleration, constant speed, and jointing. It maximizes the equipment's speed potential, allowing operators to increase speed with greater confidence, as the system automatically ensures sufficient adhesive supply during acceleration. This increases production capacity while maintaining quality, significantly reducing scrap and rework rates.

[0049] Example 2 Please see Figure 2 This embodiment provides a steel wire and steel ring adhesive application control system, which includes: Acquisition module 100: used to acquire the real-time winding speed of the winding machine and the real-time operating current of the extruder; Calculation module 200: used to calculate the reference speed of the extruder based on the real-time winding speed and the preset coordination coefficient; determine the corresponding target current based on the real-time winding speed; calculate the current deviation between the target current and the real-time operating current; and generate a speed compensation amount through a closed-loop controller based on the current deviation. Control module 300: used to determine the target speed of the extruder based on the reference speed and the speed compensation amount, so as to control the extruder to operate at the target speed.

[0050] Preferably, the control module is a PID controller, used to perform proportional, integral and derivative operations on the current deviation through a PID control algorithm to generate the speed compensation amount.

[0051] It should be noted that this embodiment provides a steel ring wire adhesive application control system, including an acquisition module 100, a calculation module 200, and a control module 300. The acquisition module collects the winding speed and extruder current in real time. The calculation module generates a reference speed based on a preset coordination coefficient using feedforward calculation. Simultaneously, it determines the target current and calculates the current deviation according to a preset speed-current correspondence. Then, a closed-loop controller generates a speed compensation amount. Finally, the control module superimposes the reference speed and the compensation amount to output the target speed command, achieving precise control of the extruder. This system uses the winding speed as the master signal to achieve rapid feedforward response and the extruder current as the feedback signal to achieve dynamic and precise fine-tuning. It constructs a dual coordination mechanism of feedforward prediction and feedback compensation, which can eliminate the influence of interference factors such as rubber viscosity fluctuations, temperature changes, and equipment wear on the rubber supply accuracy in real time. It ensures that the rubber supply and wire consumption of the extruder are instantaneously matched throughout the process, significantly improving the uniformity and consistency of the adhesive application thickness, greatly reducing start-up scrap and speed fluctuation scrap, and effectively improving the product quality stability and production efficiency of the steel ring production line.

[0052] Example 3 In a preferred embodiment, this application also provides an electronic device, the electronic device comprising: The computer device includes a memory and a processor, wherein the memory stores computer-readable instructions that, when executed by the processor, implement the described steel wire and steel ring adhesive application control method. The computer device can be broadly categorized as a server, terminal, or any other electronic device with the necessary computing and / or processing capabilities. In one embodiment, the computer device may include a processor, memory, network interface, communication interface, etc., connected via a system bus. The processor of the computer device can be used to provide the necessary computing, processing, and / or control capabilities. The memory of the computer device may include a non-volatile storage medium and internal memory. The non-volatile storage medium may store an operating system, computer programs, etc. The internal memory can provide an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The network interface and communication interface of the computer device can be used to connect and communicate with external devices via a network. When the computer program is executed by the processor, it performs the steps of the method of the present invention.

[0053] This invention can be implemented as a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, causes the steps of the methods of embodiments of the invention to be performed. In one embodiment, the computer program is distributed across multiple network-coupled computer devices or processors, such that the computer program is stored, accessed, and executed in a distributed manner by one or more computer devices or processors. A single method step / operation, or two or more method steps / operations, may be executed by a single computer device or processor or by two or more computer devices or processors. One or more method steps / operations may be executed by one or more computer devices or processors, and one or more other method steps / operations may be executed by one or more other computer devices or processors. One or more computer devices or processors may execute a single method step / operation, or execute two or more method steps / operations.

[0054] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0055] The technical features described above can be combined arbitrarily. Although not all possible combinations of these technical features are described, any combination of these technical features should be considered to be covered by this specification, provided that such combination does not contain contradictions.

[0056] The specific embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any other corresponding changes and modifications made in accordance with the technical concept of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for controlling the adhesive application of steel wire in steel rings, applied to a steel ring winding production line, the production line comprising a winding machine and an extruder, characterized in that... The method includes: S100: Obtain the real-time winding speed of the winding machine and the real-time operating current of the extruder; S200. Calculate the reference rotational speed of the extruder based on the real-time winding speed and the preset coordination coefficient; S300. Determine the corresponding target current based on the real-time winding speed, calculate the current deviation between the target current and the real-time operating current, and generate a speed compensation amount through a closed-loop controller based on the current deviation. S400. Based on the reference speed and the speed compensation amount, determine the target speed of the extruder so as to control the extruder to operate at the target speed.

2. The method for controlling adhesive application on steel wires and steel rings according to claim 1, characterized in that, The closed-loop controller is a PID controller, and the generation of speed compensation based on the current deviation through the closed-loop controller includes: The speed compensation amount is generated by performing proportional, integral, and derivative operations on the current deviation using a PID control algorithm.

3. The method for controlling adhesive application to steel wires and steel rings according to claim 1, characterized in that, The method further includes: Upon receiving the start command, the extruder is started first. Obtain a rubber material arrival signal, which indicates that the rubber material output from the extruder die has reached the wire winding point; In response to the rubber material arrival signal, the winding machine is started.

4. The method for controlling adhesive application on steel wire and steel ring according to claim 1, characterized in that, The preset coordination coefficient is obtained through experimental calibration. The preset coordination coefficient is used to establish a linear mapping relationship between the real-time winding speed of the winding machine and the reference speed of the extruder.

5. The method for controlling adhesive application to steel wires in steel rings according to claim 1, characterized in that, The step of determining the corresponding target current based on the real-time winding speed specifically includes: Based on the preset relationship between winding speed and extruder operating current, determine the target current corresponding to the real-time winding speed; The relationship between the preset winding speed and the extruder operating current is obtained through experimental calibration and is used to represent the extruder operating current corresponding to the glue coating quality meeting the preset standard under different winding speeds.

6. The method for controlling adhesive application on steel wire and steel ring according to claim 1, characterized in that, The method for determining the target speed of the extruder based on the reference speed and the speed compensation amount includes: The target speed of the extruder is obtained by superimposing the reference speed and the speed compensation amount.

7. The method for controlling adhesive application on steel wire and steel ring according to claim 2, characterized in that, The method further includes: The proportional coefficient, integral coefficient, and derivative coefficient in the PID control algorithm are pre-tuned so that the real-time operating current of the extruder can track the target current during the real-time winding speed change of the winding machine, and the current adjustment during the tracking process is within a first preset threshold range.

8. A steel ring and steel wire adhesive application control system, characterized in that, The method for controlling the application of adhesive to steel wires in steel rings according to any one of claims 1 to 7, wherein the system comprises: Acquisition module: used to acquire the real-time winding speed of the winding machine and the real-time operating current of the extruder; Calculation module: used to calculate the reference speed of the extruder based on the real-time winding speed and the preset coordination coefficient; determine the corresponding target current based on the real-time winding speed; calculate the current deviation between the target current and the real-time operating current; and generate a speed compensation amount through a closed-loop controller based on the current deviation. Control module: used to determine the target speed of the extruder based on the reference speed and the speed compensation amount, so as to control the extruder to operate at the target speed.

9. The steel ring and steel wire adhesive application control system according to claim 8, characterized in that, The control module is a PID controller, which is used to perform proportional, integral and derivative operations on the current deviation through the PID control algorithm to generate the speed compensation amount.

10. An electronic device, characterized in that, include: Memory; The processor, wherein the memory stores computer-readable instructions that, when executed by the processor, implement the steel wire and steel ring adhesive application control method according to any one of claims 1 to 7.

Images