A method and system for controlling the reeling of an electric wire cable

Abstract

The application relates to a wire and cable winding control method and system, and relates to the technical field of cable processing equipment. The control method comprises the following steps: S1, acquiring cable parameters and first operation parameters of a first driving device; S2, generating second operation parameters and third operation parameters through a cooperative control model based on the cable parameters and the first operation parameters; S3, controlling a second driving device according to the second operation parameters, so that the unwinding speed matches the winding speed; S4, controlling a third driving device according to the third operation parameters, and applying a constant target tension; S5, calculating the winding turns and the stacking height according to the first operation parameters and the cable parameters, and generating a height adjustment instruction; and S6, controlling a lifting device according to the height adjustment instruction, so that the outgoing wire height changes along with the stacking height. The application integrates winding, unwinding, tension and height adjustment into a unified cooperative control system, effectively reduces the disorder layer phenomenon, maintains constant tension, and improves the winding efficiency and product consistency.

Description

Technical Field

[0001] This application relates to the field of cable processing equipment technology, and in particular to a control method and system for winding up wires and cables. Background Technology

[0002] After the production and processing of wires and cables, they usually need to be continuously and neatly wound onto cable reels using winding equipment for subsequent storage, transportation, and laying. In order to obtain the maximum cable storage capacity on the cable reel with limited dimensions, and to ensure that the cable can be smoothly unwound during subsequent use without loosening, cross-over, or damage, the ideal winding process requires that the cable not only form tightly arranged coils in the transverse direction, but also achieve orderly and neat stacking layer by layer in the radial direction.

[0003] Currently, most traditional cable winding equipment lacks a constant and controllable tension adjustment mechanism. During winding, the tension on the cable fluctuates significantly, relying solely on the cable's own weight or simple friction components to provide weak tension. This results in the cable not tightly adhering to the lower layer of cable and the cable reel surface during winding, leading to numerous gaps inside the wound reel, making it loose and fluffy overall. This not only significantly reduces the effective storage capacity of the cable reel but also increases the risk of cable loosening and displacement during transportation. Furthermore, common cable winding equipment on the market typically consists of independent winding drive mechanisms and reciprocating cable laying mechanisms. For example, a variable frequency motor drives the cable reel to rotate for winding, while an independent servo motor or mechanical cam mechanism drives the cable laying device to reciprocate for laying. In terms of control methods, these devices mostly use independent control loops, meaning the speed of the winding motor, the speed of the cable laying motor, and the parameters of the tension mechanism are set separately by the operator based on experience.

[0004] However, existing technical solutions generally suffer from the following drawbacks in practical production applications: First, due to the lack of real-time linkage calculation between the winding speed and the cable laying speed based on cable parameters (such as wire diameter), the cable laying speed often cannot accurately follow changes in the winding speed, resulting in sparse, overlapping, or cross-stacking of cables on the cable reel, severely affecting the density and appearance quality of the reel. Second, tension control mostly relies on mechanical friction or gravity, and its tension value not only cannot be dynamically adjusted during the winding process but also fluctuates significantly, failing to ensure that the cable fits tightly against the lower layer of cable and the reel surface. This results in a large number of gaps inside the wound reel, significantly reducing the effective cable storage capacity of the same specification cable reel. In addition, the height of the cable laying mechanism is mostly fixed and cannot automatically rise as the cable stacking height increases, causing the incident angle of the cable entering the cable reel to constantly change, further exacerbating the risks of interlayer movement and gap formation. Although some highly automated equipment has introduced PLC controllers, they are limited to closed-loop control of the target position of each actuator, that is, only ensuring that the cable guide can move to the preset end position, without establishing a dynamic coordination relationship between winding, cable guide and tension. Summary of the Invention

[0005] The purpose of this application is to provide a control method and system for winding up electric wires and cables to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows: This application provides a method for controlling the winding of electric wires and cables, applied to a winding device. The winding device includes a first drive device for driving the cable reel to rotate and wind, a second drive device for guiding the cable to reciprocate along the axial direction of the cable reel, a third drive device for applying winding tension to the cable, and a lifting device for adjusting the height of the cable arrangement. The control method includes the following steps: S1. Obtain the preset cable parameters and the real-time first operating parameters of the first drive device; S2. Based on the cable parameters and the first operating parameters, the second and third operating parameters are generated through a preset collaborative control model; S3. Control the operation of the second drive device according to the second operating parameters so that the cable laying speed in the current layer of the cable reel is matched with the winding speed of the first drive device in real time, so as to achieve close parallel arrangement of cables. S4. Simultaneously, the third drive device is controlled to operate according to the third operating parameters in order to apply a constant target tension to the cable; S5. Based on the first operating parameters and cable parameters, calculate the number of winding turns on the cable reel and the current stacking height in real time, and generate a height adjustment command; S6. Control the lifting device to operate according to the height adjustment command so that the cable outlet height follows the change of the current stacking height.

[0007] This application also provides a wire and cable winding system for implementing the wire and cable winding control method of any of the above, comprising: Base; The clamping mechanism, mounted on the base, includes a first motor for clamping and driving the cable reel to rotate; The guiding mechanism includes a guide block, a second motor that drives the guide block to reciprocate along the axial direction of the cable reel, and a third motor mounted on the guide block for pressing the cable to provide winding tension. The lifting mechanism, connected to the guide mechanism, is a first hydraulic cylinder used to drive the overall lifting of the guide mechanism; The control cabinet has a built-in intelligent control mechanism, and the first motor, second motor, third motor and first hydraulic cylinder are all connected to the intelligent control mechanism; The intelligent control mechanism is configured as follows: Obtain the preset cable parameters and the real-time operating parameters of the first motor; Based on the cable parameters and the first operating parameters, a second operating parameter and a third operating parameter are generated through a preset collaborative control model. The operation of the second motor is controlled according to the second operating parameter so that the cable laying speed and the winding speed are matched in real time. At the same time, the operation of the third motor is controlled according to the third operating parameter to maintain a constant winding tension. Based on the first operating parameters and cable parameters, the number of winding turns on the cable reel and the current stacking height are calculated in real time, and the first hydraulic cylinder is controlled to perform a height following action.

[0008] Furthermore, the intelligent control mechanism includes a PLC controller, which is equipped with a collaborative control model. The collaborative control model is used to simultaneously calculate the target speed of the second motor, the target torque of the third motor, and the target lifting height of the first hydraulic cylinder based on the preset cable diameter, the initial empty diameter of the cable reel, the effective winding width of the cable reel, and the real-time speed of the first motor.

[0009] The beneficial effects of the technical solution provided in this application include at least the following: (1) This application uses a collaborative control model to dynamically bind the wire laying speed and the winding speed, so that the wire laying action can be automatically adjusted according to the real-time changes in the winding speed, effectively realizing the close side-by-side arrangement of the cable on the cable reel, and improving the density and appearance of the cable reel.

[0010] (2) This application incorporates tension control into the collaborative control model for unified calculation, forming an active pressure process that can be adjusted in real time according to the winding state, so that each coil of cable can be tightly attached to the surface of the cable reel and the lower coil, thereby improving the effective wire storage capacity of the cable reel.

[0011] (3) This application improves the overall efficiency of winding operations and product consistency by integrating the control logic of four actions—winding, laying, tension and height adjustment—into a unified collaborative control system. Attached Figure Description

[0012] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the control flow of the control method in one embodiment of this application; Figure 2 This is a schematic diagram of the system structure after the cable reel is installed in one embodiment of this application; Figure 3 This is a schematic diagram of the structure in front of the cable tray in one embodiment of the present application; Figure 4 yes Figure 3 Enlarged structural diagram at point A; Figure 5 This is a schematic cross-sectional view of a partial structure of the system in one embodiment of this application; Figure 6 This is a partial structural cross-sectional view of the fixed box in one embodiment of the system of this application; Figure 7 This is a partial structural cross-sectional schematic diagram of the guide mechanism in one embodiment of the system of this application; Figure 8 This is a schematic diagram of the structure of the pressure roller in one embodiment of the system of this application; Figure 9 This is a schematic diagram of the structure of the insertion post in one embodiment of the system of this application.

[0013] Explanation of key figure labels: 1. Base; 11. Electric bracket; 2. Fixed box; 21. Partition; 211. Second slide rail; 3. Second hydraulic cylinder; 4. First motor; 41. Second slider; 5. Rotating shaft; 51. Fixed plate; 52. Insert post; 521. Mounting slot; 53. Camera; 6. Cable reel; 61. First socket; 62. Second socket; 7. Adjusting post; 71. First slide rail; 72. First slider; 721. Internal thread; 73. Connecting plate; 74. Guide block; 741. Wire hole; 742. Through groove; 75. Rotating rod; 751. External thread; 76. Second motor; 77. Third motor; 771. Pressure roller; 8. First hydraulic cylinder; 9. Control cabinet. Detailed Implementation

[0014] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0015] In this specification, identical components are represented by the same reference numerals. The terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more. Example 1

[0016] See Figure 1 A method for controlling the winding of electric wires and cables is applied to a winding device. The winding device includes a first drive device for driving the cable reel to rotate and wind, a second drive device for guiding the cable to reciprocate along the axial direction of the cable reel, a third drive device for applying winding tension to the cable, and a lifting device for adjusting the height of the cable laying. The control method includes the following steps: S1. Obtain the preset cable parameters and the real-time first operating parameters of the first drive device; S2. Based on the cable parameters and the first operating parameters, the second and third operating parameters are generated through a preset collaborative control model; S3. Control the operation of the second drive device according to the second operating parameters so that the cable laying speed in the current layer of the cable reel is matched with the winding speed of the first drive device in real time, so as to achieve close parallel arrangement of cables. S4. Simultaneously, the third drive device is controlled to operate according to the third operating parameters in order to apply a constant target tension to the cable; S5. Based on the first operating parameters and cable parameters, calculate the number of winding turns on the cable reel and the current stacking height in real time, and generate a height adjustment command; S6. Control the lifting device to operate according to the height adjustment command so that the cable outlet height follows the change of the current stacking height.

[0017] In this embodiment, in step S1, before or during the winding operation, the operator can pre-input the basic parameters of the cable to be wound through a human-machine interface. These cable parameters include at least the cable diameter. Simultaneously, the control unit collects the current operating status of the first drive device in real time to obtain first operating parameters. These first operating parameters include at least the current rotational speed or angular velocity of the first drive device. The cable parameters determine the required lateral step size for cable laying, while the first operating parameters reflect the real-time winding speed; together, they constitute the basic input for subsequent collaborative calculations.

[0018] In step S2, a preset collaborative control model is deployed within the control unit. This model uses the cable parameters and first operating parameters obtained in step S1 as input variables, and after calculation, synchronously outputs second and third operating parameters. The second operating parameter controls the action of the second drive device, and the third operating parameter controls the action of the third drive device. This collaborative control model establishes a dynamic functional relationship between the winding action, the cable laying action, and the tension application action, enabling the operating commands of the latter two to automatically adjust in real time according to changes in the winding action, rather than being set independently.

[0019] In step S3, the control unit sends the second operating parameters generated in step S2 to the second drive device, driving it to run at a specified speed and direction. The second drive device drives the guide component to reciprocate along the axial direction of the cable reel. Since the second operating parameters are dynamically calculated based on the real-time first operating parameters and the cable diameter, the cable laying speed can be adjusted synchronously and proportionally when the winding speed is increased or decreased due to process requirements, ensuring that the guide component moves laterally by exactly one cable diameter for each rotation of the cable reel. Therefore, the cable can be arranged closely side-by-side on the current winding layer, effectively reducing sparse gaps or overlaps between cables.

[0020] In step S4, while the cable laying action is being performed in step S3, the control unit simultaneously sends the third operating parameter generated in step S2 to the third drive device. The third drive device operates according to this parameter, continuously applying a reverse tension force along the winding direction to the cable surface through a pressure-applying element connected to its output end. Since the third operating parameter is also calculated by the collaborative control model based on the real-time winding state, the tension applied to the cable can be maintained at a preset constant level throughout the entire winding process, regardless of the winding speed, without tension fluctuations caused by sudden speed changes or mechanical friction variations.

[0021] In step S5, as the winding operation continues, the number of turns and radial stacking layers of the cable on the cable reel continuously increase. The control unit performs time integration based on the rotation speed information in the first operating parameters to obtain the total number of rotations of the cable reel since winding began. Combining the known cable diameter, the initial empty diameter of the cable reel, and the effective winding width of the cable reel, the control unit can calculate in real time the number of turns already wound, the current winding layer, and the stacking height of the current layer of cable surface relative to the reference plane. Based on this real-time calculated stacking height, the control unit generates a corresponding height adjustment command.

[0022] In step S6, the control unit sends the height adjustment command generated in step S5 to the lifting device. Upon receiving the command, the lifting device drives the entire cable delivery mechanism to move vertically, ensuring that the cable exit point height when entering the cable reel is always aligned with the height of the current stack layer or at an optimal angle of incidence. This height-following action reduces the problem of cable angle changes caused by the gradually increasing diameter of the cable reel, allowing each newly wound layer of cable to be laid flat on top of the lower layer, further ensuring the neatness of the radial stacking.

[0023] Steps S1 to S6 are executed cyclically during the winding process until winding is complete, thereby achieving full-process dynamic coordinated control of the four actions: winding, cable laying, tension, and height following.

[0024] The above method uses a collaborative control model to dynamically bind the cable laying speed and winding speed, enabling the cable laying action to automatically adjust according to real-time changes in the winding speed. This ensures that the cable laying mechanism advances exactly one cable diameter for each revolution of the cable reel. This effectively achieves a tight, side-by-side arrangement of cables laterally on the cable reel, avoiding problems such as excessive gaps, cross-stacking, and misaligned wires caused by speed mismatch, significantly improving the density and uniformity of the cable reel.

[0025] Simultaneously, tension control is incorporated into the collaborative control model for unified calculation, so that the tension application action is no longer an isolated mechanical friction or fixed value setting, but forms an active pressure application process that can be adjusted in real time according to the winding state. During the winding process, the tension on the cable remains constant, so that each turn of cable can be tightly attached to the surface of the cable reel and the lower coil, reducing residual gaps inside the reel and increasing the effective cable storage capacity of the cable reel.

[0026] In addition, the stacking height is calculated in real time based on the number of winding turns and cable parameters, and the lifting device is driven to follow the height, so that the cable exit height always matches the height of the current winding layer. This effectively reduces the negative effect of the cable incident angle constantly changing due to the increase in stacking height, and effectively ensures that the cable can be stacked smoothly and flat layer by layer.

[0027] This method integrates the control logic of four core actions—winding, cable laying, tension, and height adjustment—into a unified collaborative control system. Operators only need to preset basic cable parameters, and the entire winding process is automatically calculated and executed by the control unit. This not only reduces the requirements for operator experience and skills, and minimizes equipment wear and cable damage caused by manual setting errors, but is also well-suited for high-volume, continuous cable production scenarios, significantly improving the overall efficiency of winding operations and product consistency.

[0028] In the specific structure of the cooperative control model, S2 further includes: the second operating parameters include the speed and / or steering of the second drive unit, and the cooperative control model is based on the formula: The rotational speed of the second drive unit is calculated, where, Let be the rotational speed of the second drive unit, D be the cable diameter, and d be the lead constant of the transmission mechanism. The first driving device angular velocity is the first operating parameter.

[0029] Specifically, S5 further includes: S51. Integrate the rotational speed in the first operating parameter over time to obtain the total number of rotations; S52. Calculate the current number of winding layers based on the total number of rotations, the initial empty diameter of the cable reel, and the cable diameter in the cable parameters; S53. Calculate the current stacking height based on the current number of winding layers and cable diameter.

[0030] In addition, the collaborative control model uses a cross-coupling control strategy to calculate the synchronization error between the first operating parameter of the first drive device and the second operating parameter of the second drive device in real time, and compensates and corrects the second operating parameter and / or the first operating parameter according to the synchronization error to eliminate the dynamic deviation between the winding speed and the take-up speed.

[0031] In this embodiment, in step S2, the second operating parameter specifically includes the rotational speed and / or direction of the second drive device. To achieve precise linear matching between the wire laying speed and the winding speed, the cooperative control model in this embodiment incorporates the following mathematical relationship: In the formula: is the target rotational speed of the second drive device, in revolutions per second (r / s) or revolutions per minute (r / min); D is the preset cable diameter, in millimeters (mm) or meters (m); d is the lead constant of the cable drive mechanism, that is, the distance the guide component moves laterally when the second drive device rotates once, in millimeters per revolution (mm / r). The real-time angular velocity of the first drive unit is expressed in radians per second (rad / s).

[0032] The control unit collects the angular velocity of the first drive device in real time at a fixed sampling period. By substituting this along with the preset cable diameter D and the system's known lead constant d into the above formula, the target rotational speed that the second drive unit should output can be calculated in real time. Simultaneously, the control unit determines the timing of the steering switch for the second drive unit based on the end limit signal of the cable's reciprocating motion. When the winding process accelerates, Increase Increase proportionally and synchronously; when the winding process decelerates. The speed is reduced accordingly. As a result, the cable laying speed always maintains a precise linear relationship with the winding speed, ensuring that the cable laying mechanism advances exactly one cable diameter for every revolution of the cable reel.

[0033] In step S5, the process of calculating the number of winding turns on the cable reel and the current stacking height in real time further includes the following sub-steps: In step S51, the control unit performs continuous time integration calculations on the real-time rotational speed of the first drive device from the start of winding. Specifically, if the first operating parameter is angular velocity... If (t), then the total number of rotations N can be expressed as: In practical digital control systems, this integral operation is achieved by accumulating the angular displacement increment within each sampling period. This allows the control unit to accurately determine the total number of complete rotations the cable reel has completed since the start of winding.

[0034] In step S52, after obtaining the total number of rotations N, the control unit combines this with the known initial empty diameter of the cable reel. The effective winding width W of the cable reel and the cable diameter D are used to calculate the number of layers L currently being wound up using geometric relationships.

[0035] The calculation method in this embodiment is as follows: First, calculate the number of cable turns that the first layer can accommodate. Where W is the effective winding width of the cable reel. As the number of layers increases, the winding circumference of each layer gradually increases. The control unit accumulates the number of turns layer by layer and compares it with N, or solves for N and... The algebraic equations related to D and W are used to derive the current number of winding layers L.

[0036] In step S53, after determining the current layer number L, the current stack height H can be calculated using the following formula: in, The initial height of the first layer of cable surface relative to the reference plane (usually equal to the cable diameter D or determined based on the empty reel structure). This stacking height H serves as the target position reference for subsequent height following by the control lifting device.

[0037] To further improve the dynamic synchronization accuracy between cable laying and winding, and to eliminate instantaneous synchronization deviations caused by factors such as response delays of various drive devices and load disturbances, the cooperative control model in this embodiment preferably adopts a cross-coupling control strategy.

[0038] Specifically, after generating the second operating parameters in step S2, the control unit also performs the following synchronization error compensation steps: First, the control unit acquires the actual first operating parameters (i.e., actual angular velocity) of the first drive device in real time. ) and the actual second operating parameters of the second drive unit (i.e., actual speed) ).

[0039] Secondly, the control unit calculates the current synchronization relationship based on the aforementioned wiring diagram. The theoretical speed that the second drive unit should achieve : Then, the control unit calculates the synchronization error. : when When the value is positive, it indicates that the cable laying speed lags behind the winding speed, and there is a risk that the cable may be stretched too tightly or laid sparsely; when... When the value is negative, it indicates that the cable laying speed is ahead of the winding speed, and the cable may pile up or cross.

[0040] Finally, the control unit will synchronize the error. As a compensation measure, the second operating parameter output is corrected in real time. For example, a proportional-integral (PI) controller can be used to... Perform calculations to generate compensation increments. And the final instructions The data is then sent to the second drive unit. In some embodiments, the synchronization error can also be fed forward to the first drive unit to fine-tune the first operating parameters.

[0041] Through the aforementioned cross-coupling control strategy, a closed-loop coupling relationship is formed between the cable laying drive and the winding drive, enabling mutual constraints and real-time correction. If sudden speed fluctuations or load changes occur during the winding process, the control system can also eliminate the synchronization deviation between the two drive shafts in a short time, ensuring that the cable laying accuracy is not disturbed.

[0042] In addition, the winding equipment also includes an image acquisition device, and the control method also includes an automatic feeding control step: The image acquisition device is controlled to acquire real-time images of the cable reel end face and identify the positions of preset docking feature points on the cable reel end face; Based on the deviation between the real-time position of the docking feature point and the target docking position, a fine-tuning command is generated to control the first drive device to perform a corner fine-tuning action until the docking feature point is aligned with the target docking position, and then the clamping device is controlled to complete the insertion and fixing of the cable reel.

[0043] In this embodiment, before the cable winding operation begins, the empty cable reel needs to be accurately installed and clamped between the two rotating shafts, and the cable reel is precisely aligned and automatically plugged in and fixed through the following automatic feeding control steps.

[0044] Once the empty cable reel is placed in a predetermined position (e.g., on an electric bracket), the control unit activates the image acquisition device to continuously acquire real-time images of the cable reel's end face. Identifiable docking feature points are pre-set on the cable reel's end face. These docking feature points are preferably insertion holes on the cable reel's end face for mating with posts on a rotating shaft, or they can be specially marked visual positioning markers.

[0045] The control unit has a built-in image recognition algorithm that preprocesses, detects edges and extracts features from each frame of the acquired image, identifies the contours or patterns of preset docking feature points, and calculates the real-time two-dimensional position coordinates of the feature points in the image coordinate system.

[0046] The control unit has pre-stored reference coordinates of the target docking position, which corresponds to the ideal alignment position where the pin on the rotating shaft can be smoothly inserted into the docking feature point.

[0047] The control unit compares the real-time positions of the identified docking feature points with the target docking position and calculates the positional deviation between them. This positional deviation includes angular deviation and / or radial deviation. Based on this deviation, the control unit generates a fine-tuning command and sends it to the first drive device.

[0048] After receiving the fine-tuning command, the first drive unit performs a low-speed angular fine-tuning action, driving the rotating shaft and its pins to slowly rotate to adjust the circumferential angular position of the pins. During this process, the image acquisition device continuously acquires images, and the control unit continuously performs feature point recognition and deviation calculation, forming a closed-loop feedback control. When the deviation between the real-time position of the identified docking feature point and the target docking position is less than the preset allowable error threshold, the control unit determines that the alignment is complete and stops the fine-tuning action.

[0049] After the docking feature point is aligned with the target docking position, the control unit sends a command to the clamping device. The clamping device drives the first motor and the rotating shaft to advance horizontally along the axial direction towards the cable reel, so that the rotating shaft is inserted into the center hole of the cable reel, and at the same time, the pins on the rotating shaft are accurately inserted into the docking feature point on the end face of the cable reel. The clamping devices on both sides move synchronously or sequentially until the fixing plates on both sides clamp the two end faces of the cable reel, completing the insertion and fixing of the cable reel.

[0050] After this, the take-up device can enter the normal take-up operation process and execute the multi-axis collaborative control steps in the aforementioned embodiments.

[0051] Through the above-described automatic feeding control steps, this embodiment achieves fully automated operation of the cable reel from placement to clamping and fixing, eliminating the need for manual intervention in the alignment process, and significantly improving feeding efficiency and equipment safety. Example 2

[0052] Please see Figures 2-9 A cable winding system for implementing a method for controlling cable winding includes a base 1, a clamping mechanism, a guiding mechanism, a lifting mechanism, and a control cabinet 9. The clamping mechanism, mounted on the base 1, includes a first motor 4 for clamping and driving the cable reel 6 to rotate. The guiding mechanism includes a guide block 74, a second motor 76 for driving the guide block 74 to reciprocate along the axial direction of the cable reel 6, and a third motor 77 mounted on the guide block 74 for pressing the cable to provide winding tension. The lifting mechanism is connected to the guiding mechanism and includes a first hydraulic cylinder 8 for driving the overall lifting of the guiding mechanism. The control cabinet 9 has a built-in intelligent control mechanism, and the first motor 4, the second motor 76, the third motor 77, and the first hydraulic cylinder 8 are all connected to the intelligent control mechanism. The intelligent control mechanism is configured as follows: Obtain the preset cable parameters and the real-time operating parameters of the first motor 4; Based on the cable parameters and the first operating parameters, a second operating parameter and a third operating parameter are generated through a preset collaborative control model. The operation of the second motor 76 is controlled according to the second operating parameter so that the cable laying speed and the winding speed are matched in real time. At the same time, the operation of the third motor 77 is controlled according to the third operating parameter to maintain a constant winding tension. Based on the first operating parameters and cable parameters, the number of winding turns on the cable reel 6 and the current stacking height are calculated in real time, and the first hydraulic cylinder 8 is controlled to perform a height following action.

[0053] The guiding mechanism also includes an adjusting column 7, a first slider 72, and a rotating rod 75. The adjusting column 7 is arranged vertically and fixedly connected to the piston rod of the first hydraulic cylinder 8. A first groove 71 extending along its length is provided on the adjusting column 7. The first slider 72 is slidably connected in the first groove 71. The guide block 74 is fixedly connected to the first slider 72 through a connecting plate 73. The rotating rod 75 is rotatably connected to the adjusting column 7 through a bearing and passes through the first groove 71. An external thread 751 is provided on the rod body of the rotating rod 75 located in the first groove 71. An internal thread 721 meshing with the external thread 751 is provided on the first slider 72. A second motor 76 is fixedly installed at one end of the adjusting column 7 and its output end is coaxially connected to the rotating rod 75. It is used to drive the rotating rod 75 to rotate so as to drive the first slider 72 and the guide block 74 to reciprocate along the first groove 71.

[0054] The guide block 74 has a wire hole 741 for the cable to pass through and a through groove 742 connected to the wire hole 741; the third motor 77 is fixedly installed on the guide block 74, and the output end of the third motor 77 is fixedly connected to a pressure roller 771. The pressure roller 771 passes through the through groove 742 and extends into the wire hole 741. The third motor 77 drives the pressure roller 771 to rotate actively to press and transport the cable.

[0055] The clamping mechanism includes a fixed box 2 and a second hydraulic cylinder 3. The fixed box 2 is provided with a partition 21, and a second slide groove 211 is provided on the partition 21. A second slider 41 is welded to the first motor 4. The second slider 41 is slidably connected in the second slide groove 211. The second hydraulic cylinder 3 is connected to the second slider 41 to drive the first motor 4 to slide horizontally to clamp or release the cable reel 6. The second hydraulic cylinder 3 is connected to the intelligent control mechanism. The output end of the first motor 4 is fixed with a rotating shaft 5. The rotating shaft 5 is provided with a post 52 for inserting the cable reel 6. The center of the end of the post 52 is provided with a mounting groove 521. A camera 53 is installed in the mounting groove 521. The camera 53 is electrically connected to the intelligent control mechanism and is used to collect images of the end face of the cable reel 6 to identify the docking feature point. The intelligent control mechanism controls the first motor 4 to perform fine-tuning of the rotation angle according to the position of the docking feature point.

[0056] The base 1 is also equipped with an electric bracket 11 for supporting the cable reel 6. The electric bracket 11 is connected to the intelligent control mechanism and is used to perform automatic lifting under the control of the intelligent control mechanism to assist in loading and unloading.

[0057] In addition, the intelligent control mechanism includes a PLC controller, which is equipped with a collaborative control model. The collaborative control model is used to simultaneously calculate the target speed of the second motor 76, the target torque of the third motor 77, and the target lifting height of the first hydraulic cylinder 8 based on the preset cable diameter, the initial empty diameter of the cable reel, the effective winding width of the cable reel, and the real-time speed of the first motor 4.

[0058] In this embodiment, as Figure 2 , Figure 3 As shown, the system includes a base 1, which is made of thickened steel to ensure the stability of the equipment operation. A pair of fixed boxes 2 are symmetrically welded and installed on the base 1, and a first motor 4 is slidably connected inside the fixed boxes 2. Specifically, a partition 21 is welded inside the fixed box 2, and a second sliding groove 211 is opened on the partition 21. A second slider 41 is welded to the bottom of the first motor 4, and the second slider 41 is slidably engaged in the second sliding groove 211 to achieve stable horizontal sliding of the first motor 4. A second hydraulic cylinder 3 is fixedly installed on the outer wall of the fixed box 2 by bolts. The piston rod end of the second hydraulic cylinder 3 is welded and fixed to the housing of the first motor 4. By extending and retracting the second hydraulic cylinder 3, the horizontal sliding of the first motor 4 is precisely controlled to complete the clamping and disassembly of the cable reel 6.

[0059] A clamping mechanism is mounted on the base 1 to reliably clamp the cable reel 6 and drive its rotation for winding. The clamping mechanism includes a pair of opposing first motors 4, which are installed inside a fixed housing 2. The output ends of each first motor 4 are coaxially welded with a rotating shaft 5. A fixed plate 51 is welded to one end of each rotating shaft 5. The fixed plate 51 has a frosted friction surface on its end face that contacts the cable reel 6 to enhance clamping friction and prevent slippage during winding. Four pins 52 are evenly welded to the rotating shaft 5 and the inner side of the fixed plate 51. A first insertion hole 61 matching the rotating shaft 5 is opened at the center of the cable reel 6, and a second insertion hole 62 corresponding to each pin 52 is opened on its end face. The pins 52 and the second insertion holes 62 are inserted into each other to prevent relative slippage between the cable reel 6 and the rotating shaft 5, ensuring stable transmission of winding power. When the pair of rotating shafts 5 rotate synchronously, they drive the cable reel 6 to rotate coaxially, completing the cable winding action. The real-time operating status of the first motors 4 (such as speed and angular velocity) is collected by the intelligent control mechanism as the first operating parameter.

[0060] like Figure 5 , Figure 6 , Figure 7 and Figure 8 As shown, a guide mechanism is provided on the base 1. The guide mechanism includes an adjusting column 7. A first slide groove 71 is formed inside the adjusting column 7 along its length. A first slider 72 is slidably connected in the first slide groove 71. A rotating rod 75 is rotatably connected to the adjusting column 7 via a bearing. The rotating rod 75 vertically passes through the first slide groove 71. The rod body located in the first slide groove 71 is machined with an external thread 751. The first slider 72 is machined with an internal thread 721 that meshes with the external thread 751, forming a screw-slider transmission structure. A second motor 76 is fixedly installed at the top of the adjusting column 7. The output end of the second motor 76 is coaxially connected to the rotating rod 75. By rotating the second motor 76 in both forward and reverse directions, the rotating rod 75 is driven to rotate, thereby driving the first slider 72 to slide stably back and forth along the first slide groove 71.

[0061] The first slider 72 has a horizontally welded connecting plate 73 at the end furthest from the adjusting column 7. A guide block 74 is integrally formed at the end of the connecting plate 73. A wire hole 741 for the cable to pass through is opened in the center of the guide block 74. The inner wall of the wire hole 741 is treated with smooth rounded corners to avoid scratching the cable sheath. A third motor 77 is fixedly installed on the guide block 74. A through groove 742 communicating with the wire hole 741 is opened on the guide block 74. A pressure roller 771 is welded to the output end of the third motor 77. The pressure roller 771 extends into the wire hole 741 through the through groove 742. The outer wall of the pressure roller 771 is covered with a rubber anti-slip layer to press the cable surface.

[0062] The control cabinet 9 is fixedly installed inside the base 1 or independently located on one side of the equipment, and houses an intelligent control mechanism. This intelligent control mechanism can be a PLC (Programmable Logic Controller), an industrial computer, or an embedded microcontroller, or other control unit with computational processing capabilities. The drivers for the first motor 4, the second motor 76, and the third motor 77, as well as the solenoid valve of the first hydraulic cylinder 8, are all electrically connected to the intelligent control mechanism via signal and power lines. The intelligent control mechanism can send control commands to each actuator and receive real-time feedback signals from each motor, enabling coordinated operation and parameter control of all components.

[0063] Before the cable winding operation begins, the empty cable reel 6 is first installed on the clamping mechanism. The second hydraulic cylinder 3 is activated, pushing the first motor 4 to slide towards the cable reel 6, causing the rotating shaft 5 to insert into the first insertion hole 61, and the insertion post 52 to engage with the second insertion hole 62. The two fixing plates 51 clamp the end face of the cable reel 6. The end of the cable to be wound is then passed through the wire hole 741 of the guide block 74 and fixed in the fixing slot of the cable reel 6. The operator inputs preset cable parameters through the human-machine interface, which include at least the diameter of the cable to be wound.

[0064] After the take-up procedure is initiated, the intelligent control mechanism begins to execute the coordinated control function. The specific working process is as follows: First, the intelligent control mechanism acquires the preset cable parameters and collects the first operating parameters of the first motor 4 in real time. The first operating parameters include the current rotational speed or angular velocity of the first motor 4, reflecting the real-time winding speed.

[0065] Secondly, the intelligent control mechanism uses the acquired cable parameters and the first operating parameters as inputs, substituting them into a pre-deployed collaborative control model. After calculation, the collaborative control model synchronously outputs the second and third operating parameters. The second operating parameter controls the operation of the second motor 76, and the third operating parameter controls the operation of the third motor 77. This model establishes a dynamic correspondence between the winding speed, the cable laying speed, and the tension.

[0066] Then, the intelligent control mechanism controls the second motor 76 to operate according to the second operating parameters, driving the guide block 74 to reciprocate along the axial direction of the cable reel 6. Since the second operating parameters are dynamically calculated based on the real-time first operating parameters, the cable laying speed of the guide block 74 can maintain real-time matching with the winding speed of the cable reel 6. Specifically, when the winding speed increases, the cable laying speed increases proportionally; when the winding speed decreases, the cable laying speed decreases synchronously. As a result, the cables can be arranged closely side by side on the current layer of the cable reel 6.

[0067] Simultaneously, the intelligent control mechanism controls the operation of the third motor 77 according to the third operating parameters, so that the clamping element connected to the output end of the third motor 77 continuously acts on the cable surface. Since the third operating parameters are also calculated in real time by the collaborative control model based on the winding state, the winding tension applied to the cable remains at a preset constant level throughout the entire winding process, without fluctuation due to changes in the winding speed.

[0068] As the winding operation continues, the number of turns and radial stacking thickness of the cable on the cable reel 6 continuously increase. Based on continuously acquired first operating parameters and preset cable parameters, the intelligent control mechanism calculates in real time the current number of turns on the cable reel 6 and the current stacking height resulting from the layered stacking of the cable. Based on this real-time calculated stacking height, the intelligent control mechanism generates a height adjustment command and sends it to the control valve of the first hydraulic cylinder 8.

[0069] After receiving the height adjustment command, the first hydraulic cylinder 8 drives the piston rod to extend the corresponding length, causing the entire guide mechanism to rise synchronously. This ensures that the cable's exit height after passing through the guide block 74 always adaptively adjusts to the changes in the current stacking height. This height-following action ensures that the incident angle of the cable entering the cable reel 6 remains within a reasonable range, allowing the newly wound cable to be laid flat on top of the lower layer of cable.

[0070] The aforementioned processes of winding, cable laying, tension maintenance, and height tracking are carried out in a coordinated manner under the unified scheduling of the intelligent control mechanism until the winding operation is completed.

[0071] During the winding operation, the winding speed and cable spacing parameters are set via control cabinet 9, and the intelligent control mechanism simultaneously starts the first motor 4, the second motor 76, and the third motor 77. The first motor 4 drives the rotating shaft 5 and the cable reel 6 to rotate at a constant speed, realizing cable winding. The second motor 76 rotates forward and backward according to the preset speed, driving the first slider 72 and the guide block 74 to slide horizontally back and forth through the lead screw drive. The reciprocating speed is precisely matched with the speed of the cable reel 6, so that the cable forms a tightly arranged coil on the cable reel 6, avoiding cross-stacking. The third motor 77 drives the pressure roller 771 to rotate synchronously. The pressure roller 771 continuously presses the cable, so that the cable between the guide block 74 and the cable reel 6 is always kept in a constant tension state, eliminating tension fluctuations, allowing the cable to fit tightly against the lower coil and the surface of the cable reel 6, reducing internal gaps and increasing the cable storage capacity.

[0072] After winding is complete, stop all motors, start the second hydraulic cylinder 3 to retract, and drive the first motor 4 and the shaft 5 to exit the cable reel 6. Then, remove the wound cable.

[0073] The above structure effectively solves the problems of unstable tension and messy wiring in traditional equipment, avoids problems such as loose cables, jumpers, and jammed cables, and is suitable for batch winding operations of conventional specification wires and cables.

[0074] In addition, such as Figure 3 , Figure 4 and Figure 9 As shown, each plug 52 has a mounting groove 521 at its center furthest end from the rotating shaft 5. A camera 53 is fixedly installed inside the mounting groove 521, with the lens of the camera 53 facing the cable reel 6. The camera 53 is electrically connected to the intelligent control mechanism inside the control cabinet 9, enabling real-time visual recognition and alignment of the second plug 62 of the cable reel 6. The camera 53 can be a miniature industrial camera module, and a ring-shaped LED supplementary light can be optionally provided around it to ensure clear end-face images under different ambient lighting conditions. The camera 53 is electrically connected to the intelligent control mechanism inside the control cabinet 9 via a signal cable that passes through the inside of the plug 52 and the rotating shaft 5 or is laid along the surface of the rotating shaft 5.

[0075] During the automatic feeding and alignment process, the intelligent control mechanism activates camera 53 to enter continuous acquisition mode. Camera 53 captures images of the cable reel 6 end face in real time and transmits the image data to the intelligent control mechanism. The intelligent control mechanism has a built-in image processing algorithm module, which performs grayscale conversion, binarization, edge detection, and feature extraction on the received image to identify preset docking feature points. These docking feature points are preferably the center or edge features of the outline of the insertion hole on the cable reel 6 end face that mates with the insertion post 52.

[0076] The intelligent control mechanism compares the real-time position of the identified docking feature points in the image coordinate system with the pre-calibrated and stored target docking position to calculate the positional deviation. This positional deviation reflects the current angular misalignment between the insertion post 52 and the insertion hole. Based on this deviation, the intelligent control mechanism generates a fine-tuning command, controlling the first motor 4 to perform low-speed, small-angle forward and reverse rotation, i.e., angular fine-tuning. During this process, the camera 53 continuously acquires images, and the intelligent control mechanism continuously calculates the deviation and corrects the command, forming a closed-loop visual servo control. When the real-time positional deviation is reduced to within the preset allowable error threshold range, the intelligent control mechanism determines that the insertion post 52 and the insertion hole have achieved precise alignment, then stops the fine-tuning action of the first motor 4, and controls the clamping device to complete axial advancement and insertion fixation.

[0077] A pair of electric brackets 11 are symmetrically fixed on the base 1 between a pair of fixed boxes 2 using bolts. The top of the electric bracket 11 is provided with an arc-shaped groove to adapt to the curvature of the outer wall of the cable reel 6. The electric bracket 11 is also electrically connected to the intelligent control mechanism to realize automatic lifting and adjustment, eliminating the need for manual handling of the cable reel 6.

[0078] Before operation, the empty cable reel 6 is placed directly into the arc-shaped groove of the electric bracket 11. The equipment is started, and the intelligent control mechanism first controls the electric bracket 11 to slowly rise, lifting the cable reel 6 to the same horizontal height as the rotating shaft 5. At this time, the camera 53 captures the end face of the cable reel 6 in real time, identifies the precise position of the second insertion hole 62, and transmits the signal to the intelligent control mechanism. The control mechanism fine-tunes the speed of the first motor 4, driving the rotating shaft 5 and the insertion post 52 to rotate slowly until the insertion post 52 and the second insertion hole 62 are completely aligned. Then, the second hydraulic cylinder 3 is controlled to advance, completing the precise insertion of the rotating shaft 5, the insertion post 52, and the cable reel 6. No manual alignment is required throughout the process, avoiding component wear caused by alignment deviation and greatly improving assembly efficiency.

[0079] After winding is completed, the second hydraulic cylinder 3 drives the rotating shaft 5 to exit the cable reel 6. The electric bracket 11 rises simultaneously to support the cable reel 6 and prevent it from falling. Then the electric bracket 11 slowly descends to facilitate the transfer of the cable reel by the operator, reduce the intensity of manual labor, and avoid damage to the cable reel 6. It is suitable for winding operations of heavy and large-size cable reels 6, and is especially suitable for use in large-scale cable production workshops.

[0080] In the above structure, the third motor 77, in conjunction with the pressure roller 771, presses the cable in real time and maintains a constant tension, resulting in minimal tension fluctuations during the winding process. This ensures the cable fits tightly against the surface of the cable reel 6 and the lower coil, significantly reducing internal gaps in the reel and preventing cable loosening, shifting, or shaking damage during transportation. The cable laying speed is intelligently linked and matched with the rotation speed of the cable reel 6, achieving a tight horizontal arrangement and neat radial layer-by-layer stacking of the cable. This effectively reduces issues such as cross-stacking, misaligned jumpers, interlayer movement, and cable seams. The integrated intelligent control, visual alignment, automatic lifting, and height self-adaptation functions reduce manual alignment, handling, and debugging processes, lowering the labor intensity of operators. It also avoids equipment wear and cable damage caused by human error, making it suitable for batch continuous cable production scenarios and improving winding efficiency.

[0081] In the embodiments disclosed in this application, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this application according to the specific circumstances.

[0082] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A method for controlling the winding of electric wires and cables, applied to a winding device, the winding device comprising a first driving device for driving a cable reel to rotate and wind, a second driving device for guiding the cable to reciprocate along the axial direction of the cable reel, a third driving device for applying winding tension to the cable, and a lifting device for adjusting the winding height, characterized in that... The control method includes the following steps: S1. Obtain the preset cable parameters and the real-time first operating parameters of the first drive device; S2. Based on the cable parameters and the first operating parameters, generate the second and third operating parameters through a preset collaborative control model; S3. Control the operation of the second drive device according to the second operating parameters so that the cable laying speed of the cable in the current layer of the cable reel is matched with the winding speed of the first drive device in real time, so as to achieve close parallel arrangement of the cables. S4. Simultaneously, the third driving device is controlled to operate according to the third operating parameters in order to apply a constant target tension to the cable; S5. Based on the first operating parameters and the cable parameters, calculate the number of winding turns and the current stacking height on the cable reel in real time, and generate a height adjustment command; S6. Control the lifting device to operate according to the height adjustment command so that the cable outlet height follows the change of the current stacking height.

2. The control method for winding up electric wires and cables according to claim 1, characterized in that, S2 further includes: The second operating parameters include the rotational speed and / or steering of the second drive unit, and the cooperative control model is based on the formula: The rotational speed of the second drive device is calculated, wherein, Let be the rotational speed of the second drive unit, D be the cable diameter, and d be the lead constant of the transmission mechanism. The first driving device angular velocity is the first operating parameter.

3. The control method for winding up electric wires and cables according to claim 2, characterized in that, The collaborative control model employs a cross-coupling control strategy to calculate in real time the synchronization error between the first operating parameter of the first drive device and the second operating parameter of the second drive device, and compensates and corrects the second operating parameter and / or the first operating parameter based on the synchronization error to eliminate the dynamic deviation between the winding speed and the take-up speed.

4. The control method for winding up electric wires and cables according to claim 1, characterized in that, The take-up device also includes an image acquisition device, and the control method further includes an automatic feeding control step. The image acquisition device is controlled to acquire real-time images of the cable reel end face and to identify the positions of preset docking feature points on the cable reel end face; Based on the deviation between the real-time position of the docking feature point and the target docking position, a fine-tuning command is generated to control the first driving device to perform a corner fine-tuning action until the docking feature point is aligned with the target docking position, and then the clamping device is controlled to complete the insertion and fixing of the cable reel.

5. The control method for winding up electric wires and cables according to claim 1, characterized in that, S5 further includes: S51. Integrate the rotational speed in the first operating parameter over time to obtain the total number of rotations; S52. Calculate the current number of winding layers based on the total number of rotations, the initial empty diameter of the cable reel, the effective winding width of the cable reel, and the cable diameter in the cable parameters. S53. Calculate the current stacking height based on the current number of winding layers and the cable diameter.

6. A cable winding system for implementing the cable winding control method according to any one of claims 1-5, characterized in that, include: Base; A clamping mechanism, mounted on the base, includes a first motor for clamping and driving the cable reel to rotate; The guiding mechanism includes a guide block, a second motor that drives the guide block to reciprocate along the axial direction of the cable reel, and a third motor mounted on the guide block for pressing the cable to provide winding tension. A lifting mechanism, connected to the guide mechanism, includes a first hydraulic cylinder for driving the overall lifting of the guide mechanism; The control cabinet has a built-in intelligent control mechanism, and the first motor, the second motor, the third motor and the first hydraulic cylinder are all connected to the intelligent control mechanism; The intelligent control mechanism is configured as follows: Obtain the preset cable parameters and the real-time operating parameters of the first motor; Based on the cable parameters and the first operating parameters, a second operating parameter and a third operating parameter are generated through a preset collaborative control model. The operation of the second motor is controlled according to the second operating parameter so that the cable laying speed and the winding speed are matched in real time. At the same time, the operation of the third motor is controlled according to the third operating parameter to maintain a constant winding tension. Based on the first operating parameters and the cable parameters, the number of winding turns and the current stacking height on the cable reel are calculated in real time, and the first hydraulic cylinder is controlled to perform a height following action.

7. The wire and cable take-up system according to claim 6, characterized in that, The guiding mechanism also includes: An adjusting column is arranged vertically and fixedly connected to the piston rod of the first hydraulic cylinder. The adjusting column has a first sliding groove extending along its length. The first slider is slidably connected to the first groove, and the guide block is fixedly connected to the first slider through a connecting plate; A rotating rod is rotatably connected to the adjusting column via a bearing and passes through the first sliding groove. The rotating rod has an external thread on its body located in the first sliding groove, and the first slider has an internal thread that meshes with the external thread. The second motor is fixedly installed at one end of the adjusting column and its output end is coaxially connected to the rotating rod. It is used to drive the rotating rod to rotate so as to drive the first slider and the guide block to reciprocate along the first slide groove.

8. The wire and cable take-up system according to claim 7, characterized in that, The guide block has a wire hole for the cable to pass through and a through groove connected to the wire hole; The third motor is fixedly mounted on the guide block, and a pressure roller is fixedly connected to the output end of the third motor. The pressure roller passes through the through groove and extends into the wire hole. The third motor drives the pressure roller to rotate actively to press and deliver the cable.

9. The wire and cable take-up system according to claim 6, characterized in that, The clamping mechanism includes a fixed box and a second hydraulic cylinder. The fixed box is provided with a partition, and a second sliding groove is provided on the partition. A second slider is welded to the first motor. The second slider is slidably connected in the second sliding groove. The second hydraulic cylinder is connected to the second slider to drive the first motor to slide horizontally to clamp or release the cable reel. The second hydraulic cylinder is connected to the intelligent control mechanism. The output end of the first motor is fixed with a rotating shaft, and the rotating shaft is provided with a post for inserting the cable reel. A mounting groove is opened at the center of the end of the post, and a camera is installed in the mounting groove. The camera is electrically connected to the intelligent control mechanism and is used to acquire images of the cable reel end face to identify docking feature points. The intelligent control mechanism controls the first motor to perform fine-tuning of the rotation angle based on the position of the docking feature points.

10. The wire and cable take-up system according to claim 6, characterized in that, The base is also provided with an electric bracket for supporting the cable reel. The electric bracket is connected to the intelligent control mechanism and is used to perform automatic lifting under the control of the intelligent control mechanism to assist in loading and unloading.

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