Torque decoupling type composite pay-off rack and collaborative control method thereof

Abstract

The application discloses a torque decoupling type composite pay-off rack and a collaborative control method thereof, and belongs to the field of metal wire processing. The torque decoupling type composite pay-off rack comprises a rack, a main shaft assembly, a wire reel, a driving assembly and a braking assembly. The main shaft assembly is rotationally connected with the rack, and the wire reel is fixed on the main shaft assembly and coaxially arranged with the main shaft assembly. The driving assembly comprises a driving motor, a main driving wheel and a driven driving wheel. The driving motor is drivingly connected with the main driving wheel, and the driven driving wheel is fixed on the main shaft assembly and coaxially arranged with the main shaft assembly. The main driving wheel is used for contacting the driven driving wheel to drive the driven driving wheel to rotate through friction. The braking assembly comprises a pneumatic brake and a brake disc. The brake disc is fixed on the main shaft assembly, and the pneumatic brake is used for contacting the brake disc to realize friction braking. Therefore, the transmission paths of driving torque and braking torque can be separated, and the coupling problem of torque can be eliminated.

Description

Technical Field

[0001] This invention belongs to the field of metal wire processing technology, specifically relating to a torque decoupling type composite wire feeding frame and its collaborative control method. Background Technology

[0002] In the field of metal wire processing, the wire feeding frame is typically a key piece of equipment used to uniformly and stably feed coiled wire. Based on the different power transmission methods, existing wire feeding frames are mainly divided into two types: active wire feeding frames and passive wire feeding frames. Active wire feeding frames use a motor to drive the main shaft to rotate, actively feeding the wire. Their tension control principle is that a speed difference exists between the motor speed and the traction / reeling speed, thus generating tension on the wire. The advantages of this method are high tension control accuracy and fast response, making it suitable for applications requiring precise tension control. Passive wire feeding frames rely on the tension from subsequent processes (traction and reeling) to drive the coil to rotate, and use mechanical structures such as brake bands and brakes to provide damping to adjust the tension. Their advantages are simple structure and low cost, making them suitable for applications with less stringent tension requirements.

[0003] Currently, the most common wire feeding frame is a coaxial series structure, which includes a main shaft, wire reel, drive assembly, and braking assembly. The drive assembly includes a motor and a reducer; the motor drives the main shaft to rotate after being reduced in speed by the reducer. The braking assembly includes a brake, which acts directly on the main shaft to achieve braking. This structure can achieve both active and passive wire feeding. However, both the drive torque and the braking torque ultimately act on the same main shaft, causing the active and passive wire feeding modes to easily interfere with each other. Furthermore, because the drive torque and braking torque act on the same component, the system's transfer function exhibits strong coupling characteristics, making it difficult for traditional PID controllers to achieve precise decoupling, resulting in slow tension response and large overshoot. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, this invention provides a rectangular decoupled composite cable tray and its collaborative control method. The technical problem to be solved by this invention is achieved through the following technical solution: In a first aspect, the present invention provides a rectangular decoupled composite wire feeding frame, including a frame, a spindle assembly, a wire reel, a drive assembly, and a braking assembly. The spindle assembly is rotatably connected to the frame, and the wire reel is fixed on the spindle assembly and the two are coaxially arranged. The drive assembly includes a drive motor, a main drive wheel, and a driven drive wheel. The drive motor and the main drive wheel are connected by a transmission. The driven drive wheel is fixed on the spindle assembly and the two are coaxially arranged. The main drive wheel is used to contact the driven drive wheel to drive the driven drive wheel to rotate through friction. The braking assembly includes a pneumatic brake and a brake disc. The brake disc is fixed on the spindle assembly. The pneumatic brake is used to contact the brake disc to achieve friction braking.

[0005] In one embodiment of the present invention, a switching component is further included. The switching component includes a linear actuation mechanism connected to a drive component. The linear actuation mechanism is used to drive the main drive wheel to move closer to or away from the driven drive wheel.

[0006] In one embodiment of the present invention, the linear actuation mechanism includes a cylinder, a linear guide rail, and a connecting seat. The cylinder and the linear guide rail are both mounted on a frame, and the connecting seat is mounted on the linear guide rail. The cylinder is used to drive the linear guide rail to perform linear motion, and the linear guide rail is used to drive the connecting seat to perform linear motion. The drive motor and the main drive wheel are both mounted on the connecting seat.

[0007] In one embodiment of the present invention, a tension detection component is further included, which is used to detect the wire tension of the reel.

[0008] In one embodiment of the present invention, a control system is also included. The drive component, braking component, switching component, and tension detection component are all connected to the control system. The control system is used to control the drive component, braking component, and switching component to work according to the detection result of the tension detection component.

[0009] In one embodiment of the present invention, an annealing furnace coordination interface is further included, which is used to connect to the annealing furnace system, and the control system is connected to the annealing furnace coordination interface.

[0010] In one embodiment of the present invention, a spool locking assembly is further included, which is installed at one end of the spindle assembly and is used to lock and fix the spool.

[0011] Secondly, the present invention also provides a collaborative control method for a torque-decoupled composite wire-laying frame, comprising a torque-decoupled composite wire-laying frame as described above, the torque-decoupled composite wire-laying frame including a spindle assembly, a wire reel, a drive assembly, and a braking assembly, the method comprising: The drive motor of the drive assembly drives the main drive wheel to rotate. The main drive wheel contacts the driven drive wheel, and the main drive wheel uses friction to drive the driven drive wheel to rotate. When the driven drive wheel rotates, it drives the spool to rotate. The spindle assembly is braked by contacting or releasing the brake disc with the pneumatic brake of the braking assembly and by utilizing the friction between the pneumatic brake and the brake disc. Adjusting the speed of the main drive wheel adjusts the driving force of the driven drive wheel, while simultaneously adjusting the clamping force of the pneumatic brake on the brake disc adjusts the braking force of the coil, thus achieving coordinated operation between the drive and braking components.

[0012] In one embodiment of the present invention, the torque decoupling type composite wire feeder further includes a switching component, the switching component includes a linear actuation mechanism, the linear actuation mechanism is connected to the drive component, and the linear actuation mechanism is used to drive the main drive wheel to move closer to or away from the driven drive wheel. The torque decoupling type composite wire feeding frame also includes a tension detection component, which is used to detect the wire feeding tension of the wire spool; The method also includes: Based on the detection results of the tension detection component, adjust the speed of the main drive wheel and the clamping force of the pneumatic brake on the brake disc.

[0013] In one embodiment of the present invention, the torque decoupling type composite wire feeding frame further includes an annealing furnace coordination interface, which is used to connect to the annealing furnace system, and the control system is connected to the annealing furnace coordination interface; The method also includes: Based on the output data from the annealing furnace coordination interface, adjust the speed of the main drive wheel and the clamping force of the pneumatic brake on the brake disc.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: In the above-described scheme of this application, the decoupled composite wire feeding frame includes a frame, a spindle assembly, a wire reel, a drive assembly, and a braking assembly. The spindle assembly is rotatably connected to the frame, and the wire reel is fixed to the spindle assembly, with both coaxially arranged. The drive assembly includes a drive motor, a main drive wheel, and a driven drive wheel. The drive motor and the main drive wheel are connected by a transmission connection, and the driven drive wheel is fixed to the spindle assembly, with both coaxially arranged. The main drive wheel contacts the driven drive wheel to drive its rotation through friction. The braking assembly includes a pneumatic brake and a brake disc. The brake disc is fixed to the spindle assembly, and the pneumatic brake contacts the brake disc to achieve friction braking. With this structure, firstly, the main drive wheel of the drive assembly applies driving torque to the driven drive wheel, and the braking assembly applies braking torque to the spindle assembly. This allows the driving torque and braking torque to act on different components, enabling independent control without interference, thus improving control accuracy by more than five times. Furthermore, the drive and braking components in this application can work together, with the drive component overcoming inertia and the braking component fine-tuning the tension, thus achieving push-pull coordinated control of the coil rotation and further improving control accuracy. Additionally, when the drive component uses a main drive wheel to drive the driven drive wheel, the friction drive method operates at 2-3 r / min without slippage or heating, ensuring stability and reliability and solving the heating problem of the magnetic powder components. Moreover, the pay-off frame of this application can accommodate titanium wires with diameters ranging from 0.8 mm to 6.5 mm, offering a wide range of applications.

[0015] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0016] Figure 1 This is a three-dimensional schematic diagram of the wire feeding frame in an embodiment of the present invention. Figure 1 ; Figure 2 This is a front view of the wire feeding frame in an embodiment of the present invention; Figure 3 This is a top view of the wire feeding frame in an embodiment of the present invention; Figure 4 This is a side view of the wire feeding frame in an embodiment of the present invention; Figure 5 This is a three-dimensional schematic diagram of the wire feeding frame in an embodiment of the present invention. Figure 2 ; Figure 6 This is a schematic diagram of the collaborative control method of the wire feeding frame in an embodiment of the present invention.

[0017] Reference numerals: 1-Frame, 2-Spindle assembly, 3-Spindle reel, 4-Drive assembly, 41-Drive motor, 42-Main drive wheel, 43-Driven drive wheel, 5-Brake assembly, 6-Switching assembly, 61-Cylinder, 62-Linear guide rail, 63-Connecting seat. Detailed Implementation

[0018] The present invention will be further described in detail below with reference to specific embodiments, but the implementation of the present invention is not limited thereto.

[0019] In the field of metal wire processing, the wire feeding frame is a key piece of equipment used to uniformly and stably feed coiled wire. Based on the different power transmission methods, existing wire feeding frames are mainly divided into two types: active wire feeding frames and passive wire feeding frames. Active wire feeding frames use a motor to drive the main shaft to rotate, actively feeding the wire. Their tension control principle is that a speed difference is created between the wire feeding motor speed and the traction / reeling speed, thus generating tension on the wire. The advantages of this method are high tension control accuracy and fast response, making it suitable for applications requiring precise tension control. Passive wire feeding frames rely on the tension from subsequent processes (traction and reeling) to drive the coil to rotate, and use mechanical structures such as brake bands and brakes to provide damping to adjust the tension. Their advantages are simple structure and low cost, making them suitable for applications with less stringent tension requirements.

[0020] However, faced with the unique properties of titanium wire, the wide wire diameter range of 0.8mm to 6.5mm, the wide speed range of 0 to 10m / min, and the stringent requirements of the high-temperature annealing process, the aforementioned single-mode pay-off frames all exhibit insurmountable technical defects. Traditional pay-off frames (whether active or passive) employ a coaxial series structure. Their torque transmission paths are as follows: in active mode, the torque transmission path is sequentially: motor, reducer, clutch, main shaft, and spool 3; in passive mode, the torque transmission path is sequentially: spool 3 (pulled by traction force), main shaft, and brake. Both driving and braking torques ultimately act on the same main shaft. The net torque borne by the main shaft is: T_net = T_drive - T_brake - T_load, where T_drive is the driving torque, T_brake is the braking torque, and T_load is the load torque (generated by traction force). This linear superposition relationship is the physical essence of "torque coupling": two torques are directly superimposed on the same rigid body and cannot be independently controlled. Specifically, when the drive torque is adjusted, it directly affects the spindle speed, thereby changing the tension; when the braking torque is adjusted, it also directly affects the spindle speed, similarly changing the tension. The paths of their effects on tension completely overlap and cannot be distinguished, causing mutual interference in control.

[0021] Specific technical problems caused by torque coupling: First, mutual interference in control: In traditional active wire release mode, although the brake is nominally "released," residual friction still exists, and any slight change in braking force will interfere with the accuracy of motor control. Conversely, in passive mode, the motor's inertia (even when power is off) will affect the braking effect through the spindle. Second, complex dynamic response: Since the driving torque and braking torque act on the same component, the system's transfer function exhibits strong coupling characteristics, making it difficult for traditional PID controllers to achieve precise decoupling, resulting in slow tension response and large overshoot. Third, forced use of clutch switching: To avoid coupling problems, existing composite solutions have to use a clutch for "two-way" switching: in active mode, the clutch engages and the brake is fully released; in passive mode, the clutch disengages and the motor stops. This method is not decoupling in essence, but time-sharing multiplexing, which cannot achieve simultaneous operation of both, limiting the upper limit of control performance. Fourth: heat generation problem at extremely low speeds: Under extremely low speed (2-3 r / min) conditions, traditional active wire release solutions rely on magnetic powder clutches to transmit torque. Since the motor-side speed is much higher than the spindle-side speed, the magnetic powder clutch must maintain torque transmission through slip, and the slip power P = T × Almost all of it is converted into heat, causing the magnetic powder clutch to overheat and even burn out rapidly. This is precisely the consequence of the torque coupling structure forcing slip to exist—because the driving torque must be transmitted through the spindle, and the spindle speed is extremely low, the motor cannot directly operate in the low-speed range, and can only rely on the clutch slip to match the speed. Fifth, the wide diameter of the titanium wire and the annealing process exacerbate the coupling problem: fine titanium wire (0.8~2.0mm): requires extremely gentle tension control, but under the coupling structure, any disturbance will be directly transmitted to the tension, leading to the risk of wire breakage; thick titanium wire (4.5~6.5mm): requires large torque drive, but under the coupling structure, the driving torque and braking torque interfere with each other, making it difficult to simultaneously meet the dual requirements of large starting torque and stable operating tension. High-temperature annealing: the tension changes caused by thermal expansion and contraction further increase the control difficulty, and it is difficult to introduce temperature feedforward compensation under the coupling structure.

[0022] Regarding the above issues, firstly, please refer to [the relevant information]. Figures 1 to 5 This invention provides a rectangular decoupled composite wire feeding frame, including a frame 1, a spindle assembly 2, a wire spool 3, a drive assembly 4, and a braking assembly 5. The spindle assembly 2 is rotatably connected to the frame 1, and the wire spool 3 is fixed on the spindle assembly 2 and the two are coaxially arranged. The drive assembly 4 includes a drive motor 41, a main drive wheel 42, and a driven drive wheel 43. The drive motor 41 and the main drive wheel 42 are connected in a transmission manner, and the driven drive wheel 43 is fixed on the spindle assembly 2 and the two are coaxially arranged. The main drive wheel 42 is used to contact the driven drive wheel 43 to drive the driven drive wheel 43 to rotate through friction. The braking assembly 5 includes a pneumatic brake and a brake disc. The brake disc is fixed on the spindle assembly 2, and the pneumatic brake is used to contact the brake disc to achieve friction braking.

[0023] In some embodiments of this application, the frame 1 is used to support the various components and adopts a welded steel structure, which has sufficient strength and rigidity.

[0024] In some embodiments of this application, the spindle assembly 2 includes a spindle, a bearing housing, and bearings. The spindle is rotatably supported on the frame 1 by the bearings, and one end is used to mount a spool locking mechanism. The spindle is made of high-strength alloy steel and has undergone quenching and tempering treatment.

[0025] In some embodiments of this application, the drive assembly 4 further includes a reducer, and the drive motor 41 is rotatably connected to the main drive wheel 42 via the reducer. The drive motor 41 is an AC servo motor with high-precision torque control capability. The reducer is a planetary reducer with an adjustable reduction ratio of 50:1 to 200:1. The main drive wheel 42 is mounted on the output shaft of the reducer and makes frictional contact with the sidewall or outer edge of the driven drive wheel 43, driving the driven drive wheel 43 to rotate through friction. The drive wheel is made of polyurethane with a hardness of 90 Shore A and a coefficient of friction of 0.6 to 0.8, making it wear-resistant and not damaging to the titanium wire.

[0026] In some embodiments of this application, the pneumatic brake is normally open, and the braking torque can be precisely controlled by adjusting the air pressure through a proportional valve. The brake disc is fixed on the main shaft, made of cast iron, with a hardened surface, and has a ventilation and heat dissipation structure to adapt to long-term operation.

[0027] In some embodiments of this application, the driving torque acts on the driven drive wheel 43, and the braking torque acts on the main shaft. The two are physically separated but coordinated in control.

[0028] In some embodiments of this application, the torque transmission path of the drive assembly 4 is sequentially the drive motor 41, the reducer, the main drive wheel 42, and the driven drive wheel 43. The torque transmission path of the braking assembly 5 is sequentially the pneumatic brake, the brake disc, the main shaft, and the coil 3.

[0029] In the above-described scheme of this application, the decoupled composite wire feeding frame includes a frame 1, a spindle assembly 2, a wire reel 3, a drive assembly 4, and a braking assembly 5. The spindle assembly 2 is rotatably connected to the frame 1, and the wire reel 3 is fixed on the spindle assembly 2 and the two are coaxially arranged. The drive assembly 4 includes a drive motor 41, a main drive wheel 42, and a driven drive wheel 43. The drive motor 41 and the main drive wheel 42 are connected in a transmission manner, and the driven drive wheel 43 is fixed on the spindle assembly 2 and the two are coaxially arranged. The main drive wheel 42 is used to contact the driven drive wheel 43 to drive the driven drive wheel 43 to rotate through friction. The braking assembly 5 includes a pneumatic brake and a brake disc. The brake disc is fixed on the spindle assembly 2, and the pneumatic brake is used to contact the brake disc to achieve friction braking. With this structure, firstly, the main drive wheel 42 of the drive assembly 4 applies driving torque to the driven drive wheel 43, and the braking assembly 5 applies braking torque to the main shaft assembly 2. This allows the driving torque and braking torque to act on different components, enabling independent control without interference, thus improving control accuracy by more than 5 times. Furthermore, the drive assembly 4 and braking assembly 5 in this application can work together. The drive assembly 4 overcomes inertia, while the braking assembly 5 fine-tunes tension, achieving push-pull coordinated control of the rotation of the coil 3, further improving control accuracy. Additionally, when the drive assembly 4 uses the main drive wheel 42 to drive the driven drive wheel 43, the friction drive method operates at 2-3 r / min without slippage or heating, ensuring stability and reliability, and solving the heating problem of the magnetic powder element. Simultaneously, the pay-off frame of this application can accommodate titanium wires with diameters ranging from 0.8 mm to 6.5 mm, offering a wide range of applications.

[0030] In some embodiments of this application, such as Figure 1 , such as 2, Figure 3 and Figure 4As shown, the system also includes a switching component 6, which comprises a linear actuator connected to the drive component 4. The linear actuator drives the main drive wheel 42 to move closer to or further away from the driven drive wheel 43. This structure controls the contact and separation between the main drive wheel 42 and the driven drive wheel 43 via the linear actuator, allowing the drive component 4 to disengage from the driven drive wheel 43 when not in operation. This eliminates mechanical wear and motor no-load losses caused by the main drive wheel 42 constantly pressing against the driven drive wheel 43. When switching between active and passive pay-off modes, the linear actuator enables rapid engagement and disengagement between the main drive wheel 42 and the driven drive wheel 43, avoiding torque interference caused by the simultaneous action of two power sources on the reel, thus improving the reliability and response speed of mode switching. Simultaneously, when the pay-off frame operates in passive mode, the drive component 4 is completely disengaged from the reel, reducing the additional rotational inertia of the spindle assembly 2, making the braking component 5 more sensitive to tension adjustment and ensuring the stability of tension control.

[0031] In some embodiments of this application, cylinder 61 is a double-acting cylinder with a stroke of 50-100 mm and an adjustable thrust of 500-2000 N. Linear guide rail 62 ensures the straightness and repeatability of the drive wheel's forward and backward movement. Connecting seat 63 connects the cylinder piston rod and the drive wheel bracket.

[0032] In some embodiments of this application, such as Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 6As shown, the linear actuation mechanism includes a cylinder 61, a linear guide rail 62, and a connecting seat 63. Both the cylinder 61 and the linear guide rail 62 are mounted on the frame 1, and the connecting seat 63 is mounted on the linear guide rail 62. The cylinder 61 drives the linear guide rail 62 to move linearly, and the linear guide rail 62 drives the connecting seat 63 to move linearly. The drive motor 41 and the main drive wheel 42 are both mounted on the connecting seat 63. With this structure, the cylinder 61 acts as a power source, directly driving the linear guide rail 62. The linear guide rail 62 converts the thrust of the cylinder 61 into the linear displacement of the connecting seat 63. Since the drive motor 41 and the main drive wheel 42 are both fixed to the connecting seat 63, the entire drive assembly 4 moves along the guiding direction of the linear guide rail 62. The guiding accuracy of the linear guide 62 ensures the centering and repeatability of the main drive wheel 42 each time it contacts the driven drive wheel 43, preventing uneven contact pressure distribution or lateral force caused by misaligned contact, thus maintaining the stability of the friction drive. The thrust output by the cylinder 61 is transmitted to the connecting seat 63 through the linear guide 62. This thrust can be quantitatively controlled by adjusting the air pressure of the cylinder 61 according to the specifications of the driven drive wheel 43 and the required friction drive force, so that the contact pressure between the main drive wheel 42 and the driven drive wheel 43 is independent of the working state of the drive motor 41, which facilitates the establishment of stable friction coupling in the active wire feeding mode. In addition, the sliding pair of the linear guide restricts the movement of the drive assembly 4 to a single degree of freedom, reducing the movement clearance of the moving parts and improving the response consistency and mechanical reliability of the forward and backward movements of the main drive wheel 42.

[0033] In some embodiments of this application, a tension detection component is also included, which is used to detect the wire tension of the reel 3. With this structure, the tension detection component directly acquires the real-time tension value of the reel 3 during the wire feeding process, providing the feedback parameters required for closed-loop control of the drive component 4 and the braking component 5. Based on the detection result, the control system adjusts the rotational speed of the main drive wheel 42 and the clamping force of the pneumatic brake on the brake disc, so that the distribution of drive torque and braking torque is dynamically adjusted according to the wire feeding conditions, avoiding wire breakage or loosening due to tension deviating from the set value. In active wire feeding mode, the tension detection value is used to correct the output speed of the drive motor 41, so that the rotational speed of the reel 3 forms a precise speed difference match with the subsequent traction speed; in passive wire feeding mode, the tension detection value is used to adjust the braking torque of the pneumatic brake, maintaining constant tension by changing the rotational resistance of the main shaft assembly 2. When disturbances such as switching between active and passive modes or changes in annealing furnace temperature occur, the tension detection component can promptly feed back the instantaneous fluctuations in tension to the control system, achieving synchronous compensation for the drive and braking units, and ensuring the stability of the wire feeding tension under all operating conditions.

[0034] In some embodiments of this application, the tension detection component includes a pendulum-type tension sensor or a direct tension sensor. The sensor accuracy is 0.5%, and the response time is <10ms.

[0035] In some embodiments of this application, a control system is also included. The drive assembly 4, braking assembly 5, switching assembly 6, and tension detection assembly are all connected to the control system. The control system is used to control the operation of the drive assembly 4, braking assembly 5, and switching assembly 6 based on the detection results of the tension detection assembly. With this structure, the control system integrates the drive assembly 4, braking assembly 5, switching assembly 6, and tension detection assembly into a unified control closed loop. The tension signal collected by the tension detection assembly is fed back to the control system in real time. Based on the deviation between the preset tension threshold and the actual tension value, the control system synchronously adjusts the speed of the drive motor 41, the clamping force of the pneumatic brake, and the forward and backward positions of the linear actuator. In active pay-off mode, the control system prioritizes adjusting the rotational speed of the main drive wheel 42 to change the driving force of the reel 3, maintaining the tension within the set range. In passive pay-off mode, the control system adjusts the clamping force of the pneumatic brake on the brake disc to control the rotational damping of the spindle assembly 2, thereby achieving tension adjustment. During mode switching, the control system sequentially controls the linear actuator to engage or disengage the main drive wheel 42 from the driven drive wheel 43, while simultaneously pre-adjusting the drive assembly 4 and brake assembly 5 at the moment of switching to avoid sudden tension changes caused by power source switching. This structure establishes the coordinated output of drive torque and braking torque on the same control benchmark, eliminating time differences and action conflicts that may arise from independent control of each component, and improving the response speed and steady-state accuracy of pay-off tension control.

[0036] In some embodiments of this application, the control system includes a PLC or a dedicated controller, which has functions such as PID regulation, logic control, and communication.

[0037] In some embodiments of this application, an annealing furnace coordination interface is also included. This interface is used to connect to the annealing furnace system, and the control system is connected to the annealing furnace coordination interface. With this structure, the annealing furnace coordination interface connects the control system of the wire feeding frame and the annealing furnace system into a unified system. The control system obtains operating parameters such as furnace temperature and wire feeding speed through this interface, and introduces feedforward compensation in the wire feeding tension adjustment. When changes in annealing furnace temperature cause thermal expansion and contraction of the wire, the control system pre-adjusts the output speed of the drive motor 41 or the clamping force of the pneumatic brake based on the temperature signal to counteract the disturbance to the wire feeding tension caused by changes in wire length, preventing tension fluctuations from being transmitted to the internal structure of the wire in the high-temperature section. When the wire feeding speed of the annealing furnace changes, the control system synchronously adjusts the speed or braking torque of the main drive wheel 42 to match the wire feeding speed of the wire spool 3 with the traction speed of the annealing furnace, preventing wire accumulation or stretching due to sudden changes in speed difference. This structure allows the tension control of the pay-off frame to be no longer independent of the annealing process, but rather to be coordinated with the operating status of the annealing furnace, reducing wire size deviations and microstructure inconsistencies caused by unstable pay-off tension during the annealing process.

[0038] In some embodiments of this application, the annealing furnace coordination interface is used to connect to the annealing furnace control system, receive signals such as furnace temperature and wire speed, and use them for feedforward compensation control. The communication protocol supports industry standards such as Modbus, PROFIBUS, and Ethernet / IP.

[0039] In some embodiments of this application, a spool locking assembly is also included. This spool locking assembly is mounted at one end of the spindle assembly 2 and is used to lock and fix the spool 3. With this structure, the spool locking assembly fixes the spool 3 and the spindle assembly 2 into a rigid connection, ensuring the axial positioning and circumferential fixation of the spool on the spindle. In active pay-off mode, the drive assembly 4 transmits driving force to the sidewall of the driven drive wheel 43 via the main drive wheel 42. The spool locking assembly ensures no relative rotation between the spool and the spindle, allowing the driving torque to be effectively transmitted from the spool through the spindle assembly 2 to the subsequent braking assembly 5, preventing interruption of the torque transmission path or rotational lag due to spool loosening. In passive pay-off mode, the braking assembly 5 applies braking torque to the brake disc, which is transmitted to the spool through the spindle assembly 2. The spool locking assembly prevents the spool from spinning freely on the spindle, ensuring that the braking torque can directly act on the pay-off process. During the annealing process, the coil locking assembly maintains the fixed connection between the coil 3 and the spindle assembly 2, preventing axial movement or circumferential slippage of the coil due to thermal expansion and contraction or start-stop impact, thereby ensuring the stability of the wire feeding tension.

[0040] In some embodiments of this application, before decoupling (traditional coaxial structure): J·dω / dt = T_drive - T_brake - T_load F = K·(ω_traction - ω_spindle) Where J is the system's moment of inertia, ω is the principal axis angular velocity, T_drive is the driving torque, T_brake is the braking torque, T_load is the load torque, F is the tension, and ω_traction is the angular velocity corresponding to the traction speed. Here, T_drive and T_brake are linearly superimposed in the same equation and cannot be controlled independently.

[0041] After decoupling (the off-axis structure of this invention): J·dω / dt = T_drive_effective - T_brake - T_load F = K·(ω_traction - ω_spindle) T_drive_effective =η·T_drive Wherein, η is the drive efficiency coefficient, which depends on the contact state (clamping force, friction coefficient, etc.) between the main drive wheel 42 and the driven drive wheel 43, and can be adjusted by controlling the pressure of the cylinder 61. Although T_drive_effective and T_brake are still in the same equation in form, the key difference is that: T_drive_effective can be independently controlled by adjusting the drive wheel clamping force, drive wheel speed, etc.; T_brake is independently controlled by the pneumatic brake; the two no longer interfere with each other physically, because the drive torque does not pass through the main shaft, and the braking torque does not interfere with the drive wheel.

[0042] In some embodiments of this application, the friction pair design of the main drive wheel 42 and the driven drive wheel 43 is crucial to the invention: the frictional transmission between the main drive wheel 42 and the driven drive wheel 43. Design parameters include: Contact pressure: F_n = P_cylinder × A_piston, where P_cylinder is the pressure of cylinder 61 and A_piston is the piston area. The contact pressure must ensure sufficient friction to transmit the maximum torque while avoiding damage to the driven drive wheel 43. For titanium wire spools, a contact pressure of 500~2000N is recommended. Maximum transmitted torque: T_max = μ × F_n × R_drive, where μ is the coefficient of friction (0.6~0.8) and R_drive is the radius of the drive wheel. T_max ≥ 2 × T_required must be satisfied, with a safety margin. Wear life: Under normal operating conditions, the polyurethane drive wheel has a lifespan of over 2000 hours. Replacement after wear is convenient and cost-effective.

[0043] In some embodiments of this application, tension fluctuation is: <±2% in active mode, <±3% in passive mode, and <±1.5% in combined mode. Switching shock: tension fluctuation during switching is <±5% (traditional switching >±20%). Temperature compensation: tension changes caused by temperature fluctuations are eliminated by more than 90%. Energy consumption: the motor completely stops in passive mode, saving more than 30% of energy.

[0044] Secondly, please see Figure 2 The present invention also provides a collaborative control method for a torque-decoupled composite wire-laying frame, comprising a torque-decoupled composite wire-laying frame as described above, the torque-decoupled composite wire-laying frame including a spindle assembly, a wire reel, a drive assembly, and a braking assembly, the method comprising: The drive motor of the drive assembly drives the main drive wheel to rotate. The main drive wheel contacts the driven drive wheel, and the main drive wheel uses friction to drive the driven drive wheel to rotate. When the driven drive wheel rotates, it drives the spool to rotate. The spindle assembly is braked by contacting or releasing the brake disc with the pneumatic brake of the braking assembly and by utilizing the friction between the pneumatic brake and the brake disc. Adjusting the speed of the main drive wheel adjusts the driving force of the driven drive wheel, while simultaneously adjusting the clamping force of the pneumatic brake on the brake disc adjusts the braking force of the coil, thus achieving coordinated operation between the drive and braking components.

[0045] The beneficial effects of Embodiment 2 of the present invention and its various implementations can be found in the analysis of the beneficial effects of Embodiment 1 and its various implementations, and will not be repeated here.

[0046] In some embodiments of this application, the torque decoupling type composite wire feeder further includes a switching component, which includes a linear actuator connected to a drive component. The linear actuator is used to drive the main drive wheel to move closer to or away from the driven drive wheel. The torque decoupling type composite wire feeding frame also includes a tension detection component, which is used to detect the wire feeding tension of the wire spool; The method also includes: Based on the detection results of the tension detection component, adjust the speed of the main drive wheel and the clamping force of the pneumatic brake on the brake disc.

[0047] In some embodiments of this application, the torque decoupling type composite wire feeding frame further includes an annealing furnace coordination interface, which is used to connect to the annealing furnace system, and the control system is connected to the annealing furnace coordination interface; The method also includes: Based on the output data from the annealing furnace coordination interface, adjust the speed of the main drive wheel and the clamping force of the pneumatic brake on the brake disc.

[0048] This application provides the following specific embodiments for illustration: Example 1: Active feeding of coarse titanium wire (for annealing): Titanium wire diameter 5.0mm, feeding speed 2m / min (spindle speed approximately 2.5r / min), annealing furnace temperature 900℃. Operating procedures are as follows: First, the operator inputs the titanium wire diameter of 5.0mm via the touchscreen, and the control system automatically selects the active mode.

[0049] Next, the cylinder extends, and the drive wheel presses the coil, with the pressing force set to 1000N (the air pressure is adjusted via a proportional valve).

[0050] After that, the pneumatic brake was fully released, and the brake air pressure was 0.

[0051] Then, the motor starts and drives the main drive wheel through the reducer (reduction ratio 100:1). The main drive wheel drives the driven drive wheel to rotate, and the driven drive wheel drives the coil to rotate.

[0052] Afterwards, the tension sensor detects the tension in real time, sets the tension F_ref=50N, and the PID controller adjusts the motor speed to stabilize the actual tension F_act at 50±1N.

[0053] Afterwards, the control system receives the annealing furnace temperature signal of 900℃, calculates the temperature compensation amount based on the thermo-mechanical coupling model, and fine-tunes the motor speed.

[0054] Afterwards, run for 30 minutes and record the tension curve, with fluctuations < ±2%.

[0055] Finally, the microstructure of the titanium wire was tested after annealing. The grains were fine and uniform, and the straightness was 0.5 mm / m, which met the requirements.

[0056] Key parameters include: motor power: 3kW, reduction ratio: 100:1, drive wheel diameter: 200mm, clamping force: 1000N, tension setting: 50N, and actual tension fluctuation: 49.2~50.8N.

[0057] Example 2: Passive feeding of fine titanium wire (for annealing): Titanium wire diameter 1.2mm, feeding speed 8m / min, annealing furnace temperature 850℃. Operating procedures: First, the operator inputs a titanium wire diameter of 1.2mm, and the control system automatically selects the passive mode.

[0058] Secondly, the cylinder retracts, and the drive wheel disengages from the coil with a gap of 8mm.

[0059] After that, the motor stopped and entered standby mode.

[0060] Then, the pneumatic brake operates with an initial air pressure of 0.2 MPa.

[0061] Subsequently, the tension sensor detects the tension in real time, sets the tension F_ref=15N, and the PID controller adjusts the opening of the proportional valve to control the braking air pressure, so that the actual tension F_act is stabilized at 15±0.5N.

[0062] Afterwards, the control system receives the annealing furnace line speed of 8m / min to ensure that the line feeding speed is synchronized.

[0063] After running for 2 hours, there was no wire breakage and the tension fluctuation was <±3%.

[0064] Finally, the annealed titanium wire has excellent surface quality, with no scratches or shrinkage.

[0065] Key parameters include: brake model: pneumatic disc brake, maximum braking torque: 200 Nm, working air pressure range: 0.1~0.8 MPa, tension setting: 15 N, actual tension fluctuation: 14.7~15.3 N.

[0066] Example 3: Seamless switching (changing specifications during annealing): The production line needs to switch from fine filament (1.2mm) to coarse filament (5.0mm) while the annealing furnace is running. Operating steps: First, the current mode is passive, with the brake working pressure at 0.3 MPa and the tension stable at 15 N.

[0067] Secondly, the operator issues a switching command, and the control system enters a transition state.

[0068] Then, the drive wheel begins to move toward the reel, while the brake pressure gradually decreases to 0.1 MPa (preloaded to 80% of the target value).

[0069] Afterwards, the control system notifies the annealing furnace in advance to temporarily slow down the speed adjustment (maintain the current speed for 10 seconds).

[0070] Then, the main drive wheel contacts and presses against the driven drive wheel (taking 0.4 seconds), and the brake pressure continues to decrease to 0.

[0071] After that, the motor starts and enters active closed-loop control mode, and the tension setting is switched to 50N.

[0072] Afterwards, the normal speed control of the annealing furnace was restored.

[0073] Finally, the entire process took 0.8 seconds, and the tension curve was recorded. The maximum fluctuation was ±7% (set value 15N → instantaneous 16.2N, then stabilized at 50N). The transition was seamless and did not affect the annealing quality.

[0074] Key parameters include: switching time: 0.8s, peak tension: 16.2N (fluctuation +8%), and recovery stabilization time: 1.5s.

[0075] Example 4: Annealing temperature fluctuation compensation: The annealing furnace temperature is increased from 850℃ to 900℃ at a heating rate of 5℃ / min. Operating procedures: First, initial state: active mode, titanium wire diameter 5.0mm, tension set at 50N, actual tension 50.2N.

[0076] Secondly, the control system detected that the temperature rose from 850℃ to 855℃ (ΔT=5℃).

[0077] Then, based on the thermo-mechanical coupling model, the following calculation was performed: ΔF_thermal = α·E·A·ΔT = 8.5e-6 ×110e9 × (π×0.0025²) × 5 ≈ 0.92N.

[0078] Then, the control system calculates the feedforward compensation: ΔT_drive = -0.8 × 0.92 / 0.5 = -1.47Nm (motor torque compensation).

[0079] After that, the motor torque automatically decreased by 1.47 Nm, while the PID continued to adjust.

[0080] Afterwards, the final tension was maintained at 50.1±0.3N, with fluctuations of <±0.6%.

[0081] Finally, comparing the uncompensated case: without compensation, the tension rises to 51.5N, with a fluctuation of +3%. Compensation effect: 93% of the tension change caused by temperature is eliminated.

[0082] Example 5: Composite push-pull control (heavy load start): At startup, the coil is fully loaded with a total weight of 800kg, resulting in high static friction. Operating steps: First, the initial state: the coil is stationary, ready to start.

[0083] Secondly, the control system automatically enters the compound mode: the main drive wheel presses against the driven drive wheel with a pressing force of 800N; the drive unit outputs torque T_drive = 80% × (J·ε + T_load) = 0.8 × (120 × 0.5 + 100) = 128Nm; the braking unit applies slight damping T_brake = 5% × T_drive = 6.4Nm. During startup: the drive unit overcomes static friction, and the coil begins to rotate; the braking unit prevents speed overshoot.

[0084] Then, 0.5 seconds later, the coil reaches the target speed of 2.5 r / min and switches to pure active mode.

[0085] Then, the tension curve was recorded, with a maximum fluctuation of ±2.5%.

[0086] Finally, compared to the pure active mode (no push-pull): the tension surges to 120% of the set value at startup, with fluctuations of ±15%. Push-pull effect: startup impact reduced by 80%, tension stability improved by 6 times.

[0087] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0088] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0089] Although this application has been described herein in conjunction with various embodiments, those skilled in the art, by reviewing the accompanying drawings, disclosure, and appended claims, will understand and implement other variations of the disclosed embodiments in carrying out the claimed application. In the claims, the word "comprising" does not exclude other components or steps, and "a" or "an" does not exclude a plurality. A single processor or other unit can implement several functions listed in the claims. While different dependent claims may recite certain measures, this does not mean that these measures cannot be combined to produce good results.

[0090] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A torque decoupling type composite wire feeding frame, characterized in that, It includes a frame, a spindle assembly, a coil, a drive assembly, and a braking assembly. The spindle assembly is rotatably connected to the frame, and the coil is fixed to the spindle assembly and the two are coaxially arranged. The drive assembly includes a drive motor, a main drive wheel, and a driven drive wheel. The drive motor and the main drive wheel are connected in a transmission connection. The driven drive wheel is fixed to the main shaft assembly and the two are coaxially arranged. The main drive wheel is used to contact the driven drive wheel to drive the driven drive wheel to rotate through friction. The braking assembly includes a pneumatic brake and a brake disc. The brake disc is fixed to the main shaft assembly. The pneumatic brake is used to contact the brake disc to achieve friction braking.

2. The torque decoupling type composite wire feeding frame according to claim 1, characterized in that, It also includes a switching component, which includes a linear actuator connected to the drive component. The linear actuator is used to drive the main drive wheel to move closer to or away from the driven drive wheel.

3. The torque decoupling type composite wire feeding frame according to claim 2, characterized in that, The linear actuation mechanism includes a cylinder, a linear guide rail, and a connecting seat. The cylinder and the linear guide rail are both mounted on the frame, and the connecting seat is mounted on the linear guide rail. The cylinder is used to drive the linear guide rail to perform linear motion, and the linear guide rail is used to drive the connecting seat to perform linear motion. The drive motor and the main drive wheel are both mounted on the connecting seat.

4. The torque decoupling type composite wire feeding frame according to claim 2, characterized in that, It also includes a tension detection component, which is used to detect the wire tension of the reel.

5. The torque decoupling type composite wire feeding frame according to claim 4, characterized in that, It also includes a control system, to which the drive assembly, braking assembly, switching assembly and tension detection assembly are all connected. The control system is used to control the operation of the drive assembly, braking assembly and switching assembly based on the detection results of the tension detection assembly.

6. The torque decoupling type composite wire feeding frame according to claim 5, characterized in that, It also includes an annealing furnace coordination interface, which is used to connect to the annealing furnace system, and the control system is connected to the annealing furnace coordination interface.

7. The torque decoupling type composite wire feeding frame according to claim 1, characterized in that, It also includes a spool locking assembly, which is installed at one end of the spindle assembly and is used to lock and fix the spool.

8. A collaborative control method for a torque decoupling type composite wire feeding frame, characterized in that, The method includes a torque-decoupled composite wire-laying frame as described in any one of claims 1 to 7, the torque-decoupled composite wire-laying frame comprising a spindle assembly, a wire spool, a drive assembly, and a braking assembly, the method comprising: The drive motor of the drive assembly drives the main drive wheel to rotate, and the main drive wheel contacts the driven drive wheel. The main drive wheel uses friction to drive the driven drive wheel to rotate, and the rotation of the driven drive wheel causes the coil to rotate. The main shaft assembly is braked by contacting or releasing the brake disc through the pneumatic brake of the braking assembly and by the friction between the pneumatic brake and the brake disc. Adjusting the rotational speed of the main drive wheel adjusts the driving force of the driven drive wheel, while simultaneously adjusting the clamping force of the pneumatic brake on the brake disc adjusts the braking force of the coil, thereby achieving coordinated operation between the drive assembly and the braking assembly.

9. The collaborative control method for the torque decoupling type composite wire feeding frame according to claim 8, characterized in that, The torque decoupling type composite cable tray also includes a switching component, which includes a linear actuator connected to the drive component. The linear actuator is used to drive the main drive wheel to move closer to or further away from the driven drive wheel. The torque decoupling type composite wire feeding frame also includes a tension detection component, which is used to detect the wire feeding tension of the wire reel; The method further includes: Based on the detection results of the tension detection component, the rotational speed of the main drive wheel and the clamping force of the pneumatic brake on the brake disc are adjusted.

10. The collaborative control method for the torque decoupling type composite wire feeding frame according to claim 9, characterized in that, The torque decoupling type composite wire feeding frame also includes an annealing furnace coordination interface, which is used to connect to the annealing furnace system; The method further includes: Based on the output data of the annealing furnace coordination interface, the rotational speed of the main drive wheel and the clamping force of the pneumatic brake on the brake disc are adjusted.

Images