Environment-friendly flexible fireproof cable and anti-damage control process for its conductor preparation process

Abstract

The application is suitable for the technical field of cable manufacturing, and particularly relates to an environment-friendly flexible fireproof cable and a damage control process for a conductor preparation process of the cable, which comprises the following steps: obtaining a first image before polishing of the conductor and cumulative running time of a nylon brush wheel; obtaining a surface state characteristic value according to the first image; obtaining a pressure compensation value caused by wear of the brush wheel according to the cumulative running time and the surface state characteristic value; adjusting contact pressure between the nylon brush wheel and the conductor according to the pressure compensation value; obtaining a second image of the conductor after polishing according to the contact pressure; obtaining a wrapping tension value and a current wrapping angle under the condition that the conductor quality is qualified; determining a first wrapping head rotating speed and a first traction speed according to the wrapping tension value and the current wrapping angle; and adjusting a wire core tension value of each wire core in the multi-core cable after wrapping. Therefore, the application can solve the problem that the subsequent process is continued under the condition that there is a defect on the surface of the conductor, and the problem of amplification of the tiny defect is caused.

Description

Technical Field

[0001] This application belongs to the field of cable manufacturing technology, and in particular relates to the damage control process of environmentally friendly flexible fireproof cables and their conductor preparation process. Background Technology

[0002] Cable manufacturing begins with conductor preparation. First, copper or aluminum rods are drawn into single filaments of the required diameter using a drawing machine, and then annealed to improve their flexibility and conductivity. Next, to increase cable flexibility, multiple single filaments are stranded or bundled to form conductive cores, often using a compacting die to make the structure more compact and round. After conductor preparation, the next step is to cover the conductor with an insulation layer using an extruder. For multi-core cables, multiple insulated cores are stranded (to form a cable), possibly with filler materials added to ensure the cable's roundness. Finally, depending on the application requirements, an inner sheath, a metal armor layer (such as steel tape or wire) are added to enhance mechanical protection, and the final outer sheath is extruded to form the complete cable product.

[0003] In existing technologies, once the process parameters for each step are set, they remain unchanged throughout the entire batch production, lacking real-time perception and closed-loop adjustment of intermediate product quality. For example, in the conductor polishing process, the nylon brush wheel gradually wears down with increasing operating time, and the actual contact pressure continuously decreases, but the control system cannot detect this change, let alone automatically compensate. As a result, the first section of conductors in the same batch may be fully polished and have a smooth surface, while the later section conductors may have residual oxide layers or excessive roughness due to insufficient pressure. These defective conductors are not intercepted but continue into the wrapping process. Since the wrapping layer (mica tape, ceramicized tape) covers the conductor surface, subsequent processes cannot visually inspect the conductor quality, and the defects are thus "encapsulated" inside the cable until finished product inspection or even after on-site laying.

[0004] In multi-stage continuous production, existing technologies focus quality control on "final product inspection" or "post-process sampling inspection of key steps." The cost of conductor polishing mainly includes electricity, brush consumables, and labor, which is far lower than the cost of refractory tape in the wrapping process and the combined cost of labor and materials in the cabling process. However, traditional processes rely solely on visual sampling by operators after polishing or simply do not inspect at all, which cannot guarantee the conductor pass rate. Once a defective conductor enters the wrapping machine, the wrapping tape is irretrievably consumed on its surface; after entering the cabling machine, multiple cores are twisted together, requiring rework to disassemble the entire cable, resulting in a high material scrap rate and significant labor losses. This "produce first, inspect later" model transmits quality risks step by step, causing minor defects to be amplified into major losses in high-value-added processes.

[0005] Therefore, existing technologies have the problem of continuing to process materials with defects on the conductor surface, leading to the amplification of tiny defects. Summary of the Invention

[0006] This application provides an environmentally friendly flexible fireproof cable and a damage prevention control process for the conductor manufacturing process, which can solve the problem of continuing to proceed to subsequent processes when there are defects on the conductor surface, resulting in the amplification of tiny defects.

[0007] In a first aspect, embodiments of this application provide a damage prevention control process for cable conductor manufacturing, including: Acquire the first image of the conductor before polishing and the cumulative running time of the nylon brush wheel; Surface state feature values ​​are obtained based on the first image; wherein, the surface state feature values ​​include conductor surface roughness, oxidation degree and / or foreign matter adhesion data; The pressure compensation value caused by brush wheel wear is obtained based on the cumulative running time and the surface condition characteristic value. Adjust the contact pressure between the nylon brush wheel and the conductor according to the pressure compensation value; Obtain a second image of the conductor after polishing according to the contact pressure; If the conductor quality is determined to be acceptable based on the second image, the wrapping tension value and the current wrapping angle are obtained. The rotational speed of the first wrapping head and the first traction speed are determined based on the wrapping tension value and the current wrapping angle. After completing the wrapping according to the first wrapping head rotation speed and the first traction speed, adjust the core tension value of each core in the multi-core cable.

[0008] The technical solutions described in this application embodiment have at least the following technical effects: The damage prevention control process for cable conductor manufacturing provided in this application involves acquiring a first image of the conductor before polishing and the cumulative running time of the nylon brush wheel; obtaining surface condition characteristic values ​​based on the first image; obtaining pressure compensation values ​​caused by brush wheel wear based on the cumulative running time and surface condition characteristic values; adjusting the contact pressure between the nylon brush wheel and the conductor based on the pressure compensation values; acquiring a second image of the conductor after polishing based on the contact pressure; obtaining the wrapping tension value and the current wrapping angle when the conductor quality is determined to be acceptable based on the second image; determining the first wrapping head rotation speed and the first traction speed based on the wrapping tension value and the current wrapping angle; and adjusting the core tension value of each core in the multi-core cable after completing the wrapping based on the first wrapping head rotation speed and the first traction speed. Therefore, the damage prevention control process for cable conductor manufacturing provided in this application establishes a mandatory quality gate in the conductor polishing process, which has the lowest cost, and is beneficial in preventing unqualified conductors from entering high-value-added processes. Combining predictive compensation for brush wheel wear with feedback compensation for conductor surface condition is beneficial in achieving adaptive adjustment of polishing pressure. Core control variables such as polishing pressure, wrapping speed ratio, and multi-core tension are progressively decoupled according to the sequence of processes to avoid system oscillations caused by simultaneous adjustment of multiple variables. From conductor polishing to multi-core cabling, quality data at each critical node is collected and linked to the same core or batch, forming a complete quality data chain. This transforms quality control from traditional "endpoint inspection" to "process assurance," where the output quality of each process is verified to be qualified before being used as input for the next process, which helps ensure the stability and consistency of the finished product quality.

[0009] In one possible implementation of the first aspect, determining the first wrapping head rotation speed and the first traction speed based on the wrapping tension value and the current wrapping angle includes: The traction speed adjustment amount is calculated based on the deviation between the wrapping tension value and the preset tension target value. The second traction speed is obtained based on the traction speed adjustment amount; Based on the deviation between the target wrapping angle and the current wrapping angle, calculate the target ratio of the second wrapping head rotation speed to the second traction speed; Adjust the second winding head rotation speed and the second traction speed according to the target ratio to obtain the third winding head rotation speed and the third traction speed; The current overlap rate is calculated based on the rotational speed of the third wrapping head and the third traction speed. Based on the deviation between the current coverage rate and the target coverage rate, the third wrapping head rotation speed and the third traction speed are corrected to obtain the first wrapping head rotation speed and the first traction speed.

[0010] In one possible implementation of the first aspect, adjusting the core tension value of each core in the multi-core cable includes: The rotational speed of the virtual spindle is obtained based on the first traction speed; wherein, the virtual spindle refers to treating the multi-core cabling process as a mechanical synchronization system, introducing the virtual spindle as a unified motion reference, and each core unwinding unit as a slave axis following the virtual spindle; The unwinding motor speed of each wire core is obtained based on the rotation speed of the virtual spindle; The core tension deviation value of each core is obtained based on the core tension value. Adjust the speed of the unwinding motor corresponding to each core according to the tension deviation value of each core, thereby adjusting the tension value of each core.

[0011] In one possible implementation of the first aspect, after determining the first winding head rotation speed and the first traction speed based on the winding tension value and the current winding angle, the process further includes: Calculate the target heating power based on the rotational speed of the first wrapping head; Adjust the current heating power according to the target heating power.

[0012] In one possible implementation of the first aspect, adjusting the current heating power according to the target heating power includes: Calculate the power correction amount based on the target heating power and the current heating power; The target heating power is added to the power correction amount to obtain the final output power; Adjust the current heating power according to the final output power.

[0013] In one possible implementation of the first aspect, obtaining the pressure compensation value caused by brush wheel wear based on the cumulative running time and the surface condition characteristic value includes: The pressure regulation coefficient is determined based on the surface state characteristic values; Based on the cumulative operating time, the corresponding pressure decay amount is retrieved from the pre-established pressure decay curve; The pressure compensation value is obtained by multiplying the pressure regulation coefficient by the pressure attenuation.

[0014] In one possible implementation of the first aspect, before obtaining the wrapping tension value and the current wrapping angle, the process further includes: The tension adjustment amount is calculated based on the deviation between the wrapping tension value and the preset tension range; Adjust the wrapping tension value according to the tension adjustment amount; When the wrapping tension value exceeds the preset tension range and the duration exceeds the time threshold, an early warning or shutdown signal is triggered.

[0015] In one possible implementation of the first aspect, obtaining surface state feature values ​​based on the first image includes: The root mean square value of surface undulation is extracted from the first image to obtain the surface roughness feature value; Based on the first image, extract the proportion of red components or perform threshold segmentation to obtain the oxidation degree feature value; Based on the first image, abnormal protrusions or shadow areas are identified using an edge detection algorithm to obtain foreign object attachment feature values; The surface roughness feature value, the oxidation degree feature value, and the foreign matter adhesion feature value are weighted and fused to obtain the surface state feature value.

[0016] In one possible implementation of the first aspect, the process further includes: The surface condition of the fireproof layer of each wire core is detected online to obtain wrapping quality data; When any fireproof layer is determined to be substandard based on the wrapping quality data, the corresponding core position is recorded and an early warning or shutdown signal is triggered.

[0017] Secondly, embodiments of this application provide an environmentally friendly flexible fireproof cable, which is prepared using the process described in any one of the first aspects above.

[0018] Thirdly, embodiments of this application provide a damage prevention control process production line for cable conductor manufacturing. The damage prevention control process production line for cable conductor manufacturing includes a polishing machine, a wrapping machine, an active cable feeding frame, control equipment, and image acquisition devices installed on the inlet and outlet sides of the polishing machine. The control equipment includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements some of the processes described in the first aspect above.

[0019] It is understood that the beneficial effects of the second and third aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic flowchart of the damage prevention control process for cable conductor manufacturing provided in one embodiment of this application; Figure 2 This is a schematic diagram of the implementation process of steps S600 and S700 in the damage prevention control process of the cable conductor preparation process provided in an embodiment of this application; Figure 3 This is a schematic diagram of the implementation process of step S800 in the damage prevention control process of the cable conductor preparation process provided in an embodiment of this application; Figure 4 This is a schematic diagram of the implementation process of steps S200 and S300 in the damage prevention control process of the cable conductor preparation process provided in an embodiment of this application; Figure 5 This is a schematic diagram of the implementation process of step S780 in the damage prevention control process of the cable conductor preparation process provided in an embodiment of this application; Figure 6 This is a flowchart illustrating the surface state feature values ​​of the conductor in multiple images during the damage prevention control process of the cable conductor manufacturing process provided in an embodiment of this application. Figure 7 This is a schematic diagram of the pressure compensation value in the damage prevention control process of the cable conductor manufacturing process provided in an embodiment of this application; Figure 8 This is a schematic diagram of the structure of the control device provided in the embodiments of this application. Detailed Implementation

[0022] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0023] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0024] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0025] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrases "if determined" or "if detected [the described condition or event]" may be interpreted, depending on the context, as meaning "once determined," "in response to determination," "once detected [the described condition or event]," or "in response to detection [the described condition or event]."

[0026] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0027] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0028] In related technologies, once the process parameters for each step are set, they remain unchanged throughout the entire batch production, lacking real-time perception and closed-loop adjustment of intermediate product quality. For example, in the conductor polishing process, the nylon brush wheel gradually wears down with increasing operating time, and the actual contact pressure continuously decreases, but the control system cannot detect this change, let alone automatically compensate. As a result, the first-stage conductors in the same batch may be fully polished and have a smooth surface, while the later-stage conductors may have residual oxide layers or excessive roughness due to insufficient pressure. These substandard conductors are not intercepted but continue into the wrapping process. Since the wrapping layer (mica tape, ceramicized tape) covers the conductor surface, subsequent processes cannot visually inspect the conductor quality, and the defects are thus "encapsulated" inside the cable until finished product inspection or even on-site laying.

[0029] In multi-stage continuous production, existing technologies focus quality control on "final product inspection" or "post-process sampling inspection of key steps." The cost of conductor polishing mainly includes electricity, brush consumables, and labor, which is far lower than the cost of refractory tape in the wrapping process and the combined cost of labor and materials in the cabling process. However, traditional processes rely solely on visual sampling by operators after polishing or simply do not inspect at all, which cannot guarantee the conductor pass rate. Once a defective conductor enters the wrapping machine, the wrapping tape is irretrievably consumed on its surface; after entering the cabling machine, multiple cores are twisted together, requiring rework to disassemble the entire cable, resulting in a high material scrap rate and significant labor losses. This "produce first, inspect later" model transmits quality risks step by step, causing minor defects to be amplified into major losses in high-value-added processes.

[0030] Therefore, existing technologies have the problem of continuing to process materials with defects on the conductor surface, leading to the amplification of tiny defects.

[0031] To address the aforementioned issues, this application provides a damage control process for the fabrication of an environmentally friendly flexible fire-resistant cable and its conductor. In this process, a first image of the conductor before polishing and the cumulative running time of the nylon brush wheel are acquired; surface condition characteristic values ​​are obtained from the first image; pressure compensation values ​​due to brush wheel wear are obtained based on the cumulative running time and surface condition characteristic values; the contact pressure between the nylon brush wheel and the conductor is adjusted based on the pressure compensation value; a second image of the conductor after polishing based on the contact pressure is acquired; if the conductor quality is determined to be acceptable based on the second image, the wrapping tension value and the current wrapping angle are acquired; the first wrapping head rotation speed and the first traction speed are determined based on the wrapping tension value and the current wrapping angle; after wrapping is completed based on the first wrapping head rotation speed and the first traction speed, the core tension value of each core in the multi-core cable is adjusted. Therefore, the damage control process for the cable conductor fabrication process provided in this application establishes a mandatory quality gate in the conductor polishing process, which has the lowest cost, thus preventing unqualified conductors from entering high-value-added processes. Combining predictive compensation for brush wheel wear with feedback compensation for conductor surface condition facilitates adaptive adjustment of polishing pressure. Core control variables such as polishing pressure, wrapping speed ratio, and multi-core tension are progressively decoupled according to the sequence of processes to avoid system oscillations caused by simultaneous adjustment of multiple variables. From conductor polishing to multi-core cabling, quality data at each critical node is collected and linked to the same core or batch, forming a complete quality data chain. This transforms quality control from traditional "endpoint inspection" to "process assurance," where the output quality of each process is verified to be qualified before being used as input for the next process, which helps ensure the stability and consistency of the finished product quality.

[0032] The damage prevention control process for cable conductor manufacturing provided in this application embodiment can be applied to a production line for damage prevention control in cable conductor manufacturing. The production line includes a polishing machine, a wrapping machine, an active pay-off frame, control equipment, image acquisition devices installed on the inlet and outlet sides of the polishing machine, a pressure sensor installed at the end of the pressure actuator of the polishing machine, and a tension sensor installed on the stationary shaft of the wrapping machine and at the core inlet of the cabling machine. The image acquisition devices include an industrial camera, a ring light source, or a coaxial light source. The polishing machine, wrapping machine, and active pay-off frame can be various types of equipment used for cable production. This application embodiment does not limit the specific type of control equipment.

[0033] For example, the control device can be an industrial computer, a programmable logic controller, an embedded control system, a distributed control system, a tablet computer, a laptop computer, an ultra-mobile personal computer (UMPC), a netbook, a desktop computer, a laptop computer, a handheld computing device, etc., but is not limited to these.

[0034] To better understand the damage prevention control process for cable conductor manufacturing provided in the embodiments of this application, the specific implementation process of the damage prevention control process for cable conductor manufacturing provided in the embodiments of this application will be described by way of example below.

[0035] Figure 1 A schematic flowchart of the damage prevention control process for cable conductor manufacturing provided in this application embodiment is shown. The damage prevention control process for cable conductor manufacturing includes: S100, acquire the first image of the conductor before polishing and the cumulative running time of the nylon brush wheel.

[0036] For example, an industrial camera (such as a CCD line scan camera or area scan camera) can be installed before polishing, along with a ring light source or coaxial light source, to trigger a photograph during the conductor's uniform movement, acquiring the first image (including multiple images). The operating status of the nylon brush wheel motor is recorded by a PLC (Programmable Logic Controller) or industrial computer. When the motor current feedback value is greater than the no-load current threshold (i.e., the brush wheel contacts the conductor), a timer accumulates the total running time, accurate to 0.1 hours.

[0037] S200, obtain surface state characteristic values ​​based on the first image. These surface state characteristic values ​​include conductor surface roughness, oxidation level, and / or foreign matter adhesion data.

[0038] For example, texture features can be extracted using the Gray-Level Co-occurrence Matrix (GLCM), or surface roughness can be characterized by calculating the standard deviation (root mean square deviation) of image grayscale values; based on color space conversion (RGB to HSV), hue (H) and saturation (S) components are extracted. Copper oxidation typically manifests as a color change from reddish-brown to black, and the oxidation area ratio is calculated by setting a threshold range for the H component; an edge detection algorithm (Canny operator) combined with morphological opening and closing operations is used to identify spots or impurities in non-conductive materials, and the ratio of the foreign object area to the total area is calculated, such as... Figure 6 As shown. After normalizing the three parameters, a feature vector is constructed to obtain the surface state feature values. For example, surface roughness Ra = 3.2 μm (calculated using the standard deviation method), oxidation degree O... x =15% (i.e., oxidized pixels account for 15% of the total pixels), foreign matter attachment F o =0.5%, and after normalizing the three, construct the feature vector F=[0.65,0.30,0.05].

[0039] S300 calculates the pressure compensation value caused by brush wheel wear based on the cumulative running time and surface condition characteristics.

[0040] For example, a target surface condition characteristic value can be preset, and the pressure compensation value caused by brush wheel wear can be obtained based on the cumulative running time and surface condition characteristic value, such as... Figure 7 As shown. For example, suppose the base pressure value P0 = 100 N. When the cumulative time T = 125.3 h, the current roughness R acur =3.2 is greater than the target roughness R atar =2.8, and oxidation removal is insufficient; pressure compensation value ΔP=(T / T life )×α+β×(R acur -R atar Let T be the value of T. life =500 h, wear coefficient α=20 N, roughness coefficient β=10. Calculated, ΔP=(125.3 / 500)×20+10×(3.2−2.8)=5.012+4.0=9.012 N. Therefore, the operating pressure should be P=P0+ΔP=109.012N.

[0041] S400 adjusts the contact pressure between the nylon brush wheel and the conductor according to the pressure compensation value.

[0042] For example, a target pressure (base pressure value + pressure compensation value) can be received, the actual pressure can be read in real time by a pressure sensor, and the contact pressure between the nylon brush wheel and the conductor can be adjusted by PID controller parameters based on the target pressure and the actual pressure.

[0043] S500, acquire a second image of the conductor after polishing based on the contact pressure.

[0044] For example, an industrial camera (such as a CCD line scan camera or area scan camera) can be installed after polishing, and a ring light source or coaxial light source can be used to trigger a photograph during the conductor's uniform movement to obtain a second image.

[0045] S600: If the conductor quality is determined to be acceptable based on the second image, the wrapping tension value and the current wrapping angle are obtained.

[0046] For example, after acquiring the second image, it can be binarized. If the area of ​​regions with a gray level below 180 in the second image accounts for less than 5%, the conductor quality is determined to be acceptable. Alternatively, an image classification algorithm (such as a CNN convolutional neural network or a traditional thresholding method) can be run. If the surface roughness, oxidation degree, and foreign matter adhesion data are all below the process upper limit (e.g., Ra ≤ 3.0, O) based on the second image, the conductor quality is considered acceptable. x ≤5%,F o If the percentage is ≤0.1%, then the conductor quality is considered acceptable.

[0047] For example, the current wrapping tension value can be read in real time by a tension sensor (such as a piezoresistive or magnetic powder brake feedback), and the current wrapping angle can be obtained by reading the angle between the wrapping tape and the conductor axis through an angle encoder or Hall sensor installed on the wrapping head.

[0048] S700 determines the first winding head rotation speed and the first traction speed based on the winding tension value and the current winding angle.

[0049] For example, the rotational speed around the bag head can be set to n (revolutions per minute), the traction speed to v (meters per minute), and the current wrapping angle θ satisfying: tan(θ) = π D n / v, where D is the conductor diameter (including the wrapping layer), the traction speed adjustment amount can be calculated based on the deviation between the wrapping tension value and the preset tension target value, the first traction speed can be obtained based on the traction speed adjustment amount, and the first wrapping head rotation speed can be calculated based on the first traction speed and the current wrapping angle.

[0050] S800, after completing the wrapping according to the first wrapping head rotation speed and the first traction speed, adjusts the core tension value of each core in the multi-core cable.

[0051] For example, after wrapping is completed according to the first wrapping head rotation speed and the first traction speed, the tension value of each core in the multi-core cable can be adjusted by using a servo motor or magnetic powder clutch to control the pay-off shaft of each core according to the required pay-off tension of each core. For example, the basic core tension is set to 50N. If the actual tension of core 1 during the stranding process is detected to be 55N and core 2 to be 45N, the following adjustments are made via PID control: the pay-off motor for core 1 decreases the current, aiming to lower it to 50N; the pay-off motor for core 2 increases the current, aiming to raise it to 50N. The adjustment step size Δ = 0.5N / second is used until the tension of all cores tends to be consistent.

[0052] In one possible implementation, please refer to Figure 2 S700, determines the first winding head rotation speed and the first traction speed based on the winding tension value and the current winding angle, including: S710 calculates the traction speed adjustment based on the deviation between the wrapping tension value and the preset tension target value.

[0053] For example, the wrapping tension value T can be... act , and the preset tension target value T ref The deviation e is obtained by comparison T =T ref -T act The tension deviation is converted into an adjustment amount Δv in the traction speed via a PI (proportional-integral) controller, where Δv = K. p,T e T +K i,T ∫e T dt, where K p,T For proportional gain, K i,T This is the integral gain.

[0054] S720 obtains the second traction speed based on the traction speed adjustment amount.

[0055] For example, the traction speed adjustment can be superimposed on a preset traction speed reference value to obtain a second traction speed.

[0056] S730 calculates the target ratio of the second wrapping head rotation speed to the second traction speed based on the deviation between the target wrapping angle and the current wrapping angle.

[0057] For example, the target ratio can be calculated based on the deviation between the target's wraparound angle and the current wraparound angle. For instance, tan(θ) = π D n / v, where D is the conductor diameter (including the cladding). Based on the target cladding angle θ. ref and the current wrap-around angle θ act (Measured by the encoder), calculate the deviation eθ =θ ref −θ act Based on the deviation, the required target speed ratio R is calculated using a PI controller. target =(n / v) target The adjustment amount ultimately yields: the target ratio R target =tanθ ref / πD+ΔR, where ΔR is output by the angle deviation controller. Or R target =tan(θ ref +Δθ comp ) / πD, where Δθ comp It is generated by PI adjustment of the angle deviation.

[0058] S740 adjusts the second winding head rotation speed and the second traction speed according to the target ratio to obtain the third winding head rotation speed and the third traction speed.

[0059] For example, the rotational speed n2 of the wrapping head and the traction speed v2 can be adjusted according to the target ratio so that their ratio is equal to the target ratio R. target This yields the third winding rotation speed n3 and the third traction speed v3. These can be adjusted by allocating certain weights. For example, n3 = n2 + α Δn, v3=v2+β Δv, and satisfying Δn / Δv=R target At the same time, make n3 / v3=R target .

[0060] S750 calculates the current coverage rate based on the third wrapping head rotation speed and the third traction speed.

[0061] For example, the current overlap rate can be calculated based on the third wrapping head rotation speed and the third traction speed. For example, λ=(1− )×100%, where w is the wrapping bandwidth and θ is the wrapping angle. Since θ and n, v satisfy tanθ=πDn / v, therefore λ=1− .

[0062] S760, based on the deviation between the current coverage rate and the target coverage rate, corrects the third wrapping head rotation speed and the third traction speed to obtain the first wrapping head rotation speed and the first traction speed.

[0063] For example, the current coverage rate λ can be... act With target coverage rate λ ref By comparison, the deviation e is obtained. λ =λ ref −λ actThe deviation is converted into fine-tuning amounts for the winding head rotation speed and traction speed using a PI controller, usually achieved by correcting the speed ratio. If the overlap ratio is too high, it indicates that the pitch is too low, requiring an increase in the pitch, i.e., a decrease in the speed ratio n / v (increasing the traction speed or decreasing the winding head rotation speed). Conversely, if the overlap ratio is too low, the opposite applies.

[0064] Through steps S710 to S760, process drift caused by variations in the diameter of the wrapping disc, fluctuations in the material friction coefficient, and mechanical wear can be automatically compensated, thus helping to maintain consistent product quality. The calculations are completed in milliseconds, with a response speed far exceeding that of manual intervention, which improves the accuracy of tension control and overlap rate control. Key parameters during the adjustment process are recorded, providing a data foundation for process optimization and quality traceability. Precise control of the overlap rate helps avoid material waste and reduces equipment overload and increased energy consumption caused by improper parameters.

[0065] In one possible implementation, please refer to Figure 3 In S800, adjusting the tension value of each core in a multi-core cable includes: S810, the rotational speed of the virtual spindle is obtained based on the first traction speed. Here, the virtual spindle refers to treating the multi-core cabling process as a mechanical synchronization system, introducing a virtual spindle as a unified motion reference, and each core unwinding unit acting as a slave axis following the virtual spindle.

[0066] For example, the rotational speed of the virtual spindle can be obtained based on the first traction speed. For instance, if the first traction speed is v1 and the cable-laying pitch is L... c For every revolution of the cable-making machine, it pulls forward one pitch, therefore the virtual spindle speed n virtual The relationship with traction speed is: n virtual =v1 / L c , where n virtual The unit is rpm (revolutions per minute), v1 is m / min, L c For m / revolution.

[0067] S820 obtains the unwinding motor speed of each wire core based on the rotational speed of the virtual spindle.

[0068] For example, it can be based on the virtual spindle speed n virtual The unwinding motor speed n for each wire core is obtained. payoff,i For example, using electronic gears: n payoff,i =v1 / (πD payoff,i ) g, where D payoff,iLet be the current diameter of the unwinding reel for the i-th core (which gradually decreases as unwinding progresses), and g be the set synchronization coefficient (usually initially 1). The electronic gear ratio G of the unwinding shaft is set using a virtual spindle as the primary reference. i = Core linear velocity / Virtual spindle speed, then n payoff,i =n virtual G i Among them, G i It can be dynamically adjusted according to the diameter of the unwinding reel to keep the unwinding speed and traction speed synchronized.

[0069] S830 calculates the core tension deviation value of each core based on the tension value of each core.

[0070] For example, the tension deviation value of each wire core can be calculated based on the tension value of each wire core and the preset tension target value.

[0071] S840 adjusts the speed of the unwinding motor corresponding to each wire core according to the tension deviation value of each wire core, thereby adjusting the tension value of each wire core.

[0072] For example, an independent PID controller (or a simpler PI controller) can be used to adjust the unwinding motor speed corresponding to each wire core based on the tension deviation value of each core. For example, Δn i =K p,i e T,i +K i,i ∫e T,i dt+K d,i de T,i / dt, where Δn i This is the correction amount for the unwinding motor speed (unit: rpm). The final unwinding motor speed is: n set,i =n payoff,i +Δn i .

[0073] Through steps S810 to S840, the traction speed is decoupled from the movement of the cabling machine and unwinding motor via a virtual spindle. Each axis is both independent and unified, achieving electronic gear synchronization, which helps stabilize the cabling pitch and prevents core twisting. The unwinding motor speed is calculated based on the real-time coil diameter, enabling dynamic feedforward compensation for coil diameter changes. This reduces the adjustment burden of the tension closed-loop, resulting in faster system response and smaller overshoot. Precise tension control avoids core thinning and insulation damage caused by excessive tension, as well as buckling and skipping caused by insufficient tension, thus improving the cabling yield. Furthermore, stable tension allows for a reduction in safety margin, saving materials.

[0074] In one possible implementation, please refer to Figure 5S700, after determining the first winding head rotation speed and the first traction speed based on the winding tension value and the current winding angle, the process also includes: S770, calculate the target heating power based on the rotational speed of the first winding head.

[0075] For example, the target heating power P can be calculated based on the rotational speed n1 of the first winding head. target For example, if the length covered on the conductor by the wrapping tape in one revolution is πD (where D is the conductor diameter), then the linear velocity v of the wrapping tape is... tape =n1 πD, P target =P0+kv v tape Where P0 is the basic power (used to maintain the heater's own temperature), and kv is the speed-power coefficient (unit: W / (m / min)). S780 adjusts the current heating power according to the target heating power.

[0076] For example, the current heating power P can be... act Adjust to target heating power P target The heater output is typically regulated using a PID controller or phase-shift trigger control (for resistance heating). For example, u=K p,P e P +K i,P ∫e P dt+K d, P de P / dt, where e P =P target -P act e P The value is the power deviation, and u is the control quantity (such as the percentage of power output corresponding to the thyristor firing angle, the PWM duty cycle, etc.).

[0077] Through steps S770 to S780, the heating power automatically adjusts synchronously when the wrapping speed changes, ensuring a constant heat absorption per unit length of wrapping tape. This improves the stability of the wrapping layer's adhesion strength and bonding. This adaptive capability is particularly important for flexible production lines with multiple product types and small batches. Precisely matching power requirements helps reduce energy waste caused by overheating. Automatically reducing heating power at low speeds or in standby mode is more energy-efficient than fixed-power heating. Closed-loop power control helps reduce external disturbances and human error, ensuring highly consistent wrapping heating effects across different batches and shifts. Reduced fluctuations in key quality indicators such as wrapping layer peel strength and electrical insulation performance help lower equipment maintenance costs.

[0078] Optionally, please refer to Figure 5 S780, adjusts the current heating power according to the target heating power, including: S781 calculates the power correction amount based on the target heating power and the current heating power.

[0079] For example, a PID (proportional-integral-derivative) algorithm can be used, based on the target heating power P. target Compared with the current actual heating power P act The power correction ΔP is calculated based on the deviation. Let the power deviation be e. P =P target -P act Then the power correction ΔP = K p e P +K i ∫e P dt+K d de P / dt, where K p K i K d These are proportional, integral, and differential gains, respectively.

[0080] S782 adds the target heating power to the power correction amount to obtain the final output power.

[0081] For example, the target heating power can be directly superimposed with the power correction amount to obtain the final output power.

[0082] S783 adjusts the current heating power based on the final output power.

[0083] For example, the current heating power can be adjusted based on a linear mapping relationship between the final output power and the control signals recognizable by the actuator (heater), such as 0~10 V analog signals, 4~20 mA current, PWM duty cycle, etc. At the same time, the output is smoothed (e.g., by first-order filtering or a ramp function) to prevent sudden power changes from impacting the power grid or heating element.

[0084] Through steps S781 to S783, the feedback correction is automatically compensated when the grid voltage fluctuates, the heating element ages, or the ambient temperature changes. This is beneficial for improving the actual power fluctuation range and enhancing the consistency of the wrapping layer quality. By using output limiting and ramp functions, the impact of power step changes on the heating element and the grid is avoided, which helps extend the life of the heating element and reduce equipment maintenance costs.

[0085] In one possible implementation, please refer to Figure 4 S300, based on cumulative running time and surface condition characteristics, obtains the pressure compensation value caused by brush wheel wear, including: S310, the pressure regulation coefficient is determined based on the surface condition characteristic value.

[0086] For example, surface condition characteristics (including roughness Ra, oxidation degree O) can be used. x Foreign object attachment F o ) is mapped to a pressure regulation coefficient, for example, K s =1+w1 (Ra−Ra target )+w2 (O x -O x,target )+w3 (F o -F o,target ), where w1, w2, and w3 are weighting coefficients, and Ra target O x,target and F o,target The target surface state characteristic value.

[0087] S320 retrieves the corresponding pressure decay amount from the pre-established pressure decay curve based on the cumulative operating time.

[0088] For example, the corresponding pressure decay amount can be retrieved from a pre-established pressure decay curve (using a new brush wheel to polish a standard sample under fixed pressure, recording the change in polishing effect (such as roughness) over time. When the polishing effect drops to the target threshold, the pressure is gradually increased to restore the effect, and the correspondence between the pressure increase value and time is recorded to obtain the pressure decay curve) based on the cumulative running time.

[0089] S330, the pressure compensation value is obtained by multiplying the pressure regulation coefficient and the pressure attenuation.

[0090] For example, the pressure compensation value can be obtained by multiplying the pressure regulation coefficient by the pressure attenuation amount, i.e., the reference compensation value.

[0091] By organically combining the wear model with quality feedback (surface inspection) through the above steps S310 to S330, the timeliness and accuracy of compensation can be improved. Since the compensation amount can precisely match actual needs, it helps reduce accelerated brush wear and conductor damage caused by overcompensation, thus contributing to extending the average service life of the brush wheel.

[0092] In one possible implementation, please refer to Figure 2 In S600, before obtaining the wrapping tension value and the current wrapping angle, the process also includes: S601, calculates the tension adjustment amount based on the deviation between the wrapping tension value and the preset tension range.

[0093] For example, the wrapping tension value can be compared with a preset tension range, the deviation can be calculated, and the tension adjustment amount ΔT can be output according to the magnitude of the deviation. adj For example, ΔT adj =K T (T act -T limit ), where T limit The boundary value that is exceeded (if T) act >T max Then T limit =T max If T act <T min Then T limit =T min ), K T The preset adjustment gain.

[0094] S602, adjust the wrapping tension value according to the tension adjustment amount.

[0095] For example, the tension adjustment amount can be converted into an actual control signal for the actuator to adjust the wrapping tension value.

[0096] S603: When the wrapping tension value exceeds the preset tension range and the duration exceeds the time threshold, a warning or shutdown signal is triggered.

[0097] For example, the actual tension can be continuously monitored to see if it is within the preset tension range, and the duration of exceeding the limit can be recorded. When the duration exceeds the set time threshold, an early warning (such as an audible and visual alarm, or a visual prompt) or direct shutdown (such as an emergency stop or power cut-off) can be triggered.

[0098] Through steps S601 to S603, the wrapping tension can be stabilized within the target range, which helps reduce problems such as uneven wrapping layer thickness and material stretching deformation caused by tension fluctuations, thereby improving wrapping quality. The delayed judgment mechanism can prevent accidental shutdowns and act promptly when a true abnormality persists, effectively reducing accidents such as wrapping tape breakage, conductor damage, and equipment overload caused by abnormal tension, thus helping to reduce equipment maintenance costs and downtime losses.

[0099] In one possible implementation, please refer to Figure 4 S200, Obtain surface state feature values ​​based on the first image, including: S210, extract the root mean square value of surface undulations based on the first image to obtain the surface roughness feature value.

[0100] For example, the first image can be converted to a grayscale image by grayscale processing, the influence of uneven illumination can be eliminated by homomorphic filtering or difference method, and the standard deviation of grayscale values ​​can be calculated in the region of interest (ROI) as the surface roughness feature value.

[0101] S220: Extract the proportion of red component or perform threshold segmentation based on the first image to obtain the oxidation degree feature value.

[0102] For example, the first image can be converted to HSV (Hue-Saturation-Lightness). In the HSV space, the hue range of red is approximately 0~10° and 160~180°. The proportion of pixels within the ROI that fall within the red hue range is calculated as the oxidation degree feature value. Alternatively, thresholding can be performed directly on the hue image, marking pixels with hue values ​​exceeding the normal copper color range as oxidized pixels, and the proportion of oxidized pixels to the total number of pixels in the ROI is determined as the oxidation degree feature value.

[0103] S230: Based on the first image, an edge detection algorithm is used to identify abnormal protrusions or shadow areas to obtain foreign object attachment feature values.

[0104] For example, the Canny edge detection operator can be used to extract edge information from the image. High and low thresholds are set to preserve strong edges and suppress noise, resulting in an edge image. A closing operation (dilation followed by erosion) is performed on the edge image to connect broken edges, forming connected regions. Then, an opening operation is performed to remove small noise points. Connected regions suspected of containing foreign objects are selected based on features such as area, shape, and grayscale contrast. For example, regions with an area greater than a preset threshold (e.g., 10 pixels) and an aspect ratio within a certain range (e.g., 0.2~5). The ratio of the total area of ​​the foreign object region to the total area of ​​the ROI is determined as the foreign object attachment feature value.

[0105] S240, the surface roughness characteristic value, oxidation degree characteristic value and foreign matter adhesion characteristic value are weighted and fused to obtain the surface state characteristic value.

[0106] For example, the surface roughness characteristic value, oxidation degree characteristic value, and foreign matter adhesion characteristic value can be normalized and weighted according to a weighting coefficient (such as w). Ra =0.5, w Ox =0.4, w Fo =0.1) Weighted fusion is used to obtain surface state feature values.

[0107] Through steps S210 to S240, image preprocessing techniques such as illumination correction, color space conversion, and morphological filtering are employed, resulting in strong robustness against interference from illumination changes, surface reflections, and slight vibrations, thus reducing the false detection rate. By combining machine vision with multi-feature fusion technology, conductor surface quality inspection is upgraded from manual qualitative judgment to machine quantitative analysis, providing accurate, reliable, and multi-dimensional input for subsequent intelligent pressure compensation and process closed-loop control.

[0108] In one possible implementation, please refer to Figure 3 The process also includes: S001, online detection of the surface condition of the fireproof layer of each wire core to obtain wrapping quality data.

[0109] For example, an industrial camera (or a multi-camera array) equipped with a high-brightness ring light source or coaxial light source can be installed to detect the surface condition of the fireproof layer of each wire core online after wrapping, thereby obtaining wrapping quality data. The wrapping quality data may include the standard deviation of grayscale on the surface of the wrapping tape (reflecting the degree of wrinkling, curling, and edge alignment) and the area of ​​surface defects (identifying holes, scratches, or inclusions using edge detection and morphological analysis).

[0110] S002, when any fireproof layer is determined to be substandard based on the wrapping quality data, the corresponding core position is recorded and an early warning or shutdown signal is triggered.

[0111] For example, when any fireproof layer is determined to be substandard based on the wrapping quality data, the corresponding core position can be recorded and an early warning or shutdown signal can be triggered. For instance, the wrapping quality data includes the standard deviation of the grayscale of the wrapping tape surface and the area of ​​surface defects. If the standard deviation of the grayscale is greater than a preset threshold (e.g., 0.3) or the area of ​​surface defects is greater than a preset threshold (e.g., 1 mm²), the fireproof layer is determined to be substandard.

[0112] Through the above steps S001 to S002, online visual inspection and intelligent anomaly handling are used to upgrade the quality of fireproof layer wrapping from post-inspection, manual judgment and rough handling to a closed-loop control mode of quantitative evaluation and precise positioning, which is conducive to improving the fire safety and production economy of cable products.

[0113] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0114] Corresponding to the damage control process in the cable conductor preparation process described in the above embodiments, this application also provides an environmentally friendly flexible fireproof cable, which is prepared using the damage control process in the cable conductor preparation process described in the above embodiments.

[0115] This application also provides a damage prevention control production line for cable conductor manufacturing. The production line includes a polishing machine, a wrapping machine, an active pay-off frame, control equipment, and image acquisition devices installed at the inlet and outlet sides of the polishing machine. The image acquisition devices include an industrial camera, a ring light source, or a coaxial light source. The polishing machine, wrapping machine, and active pay-off frame can be various types of equipment used for cable production. Figure 8 This is a schematic diagram of the structure of a control device provided in one embodiment of this application. Figure 8 As shown, the control device 8 in this embodiment includes: at least one processor 80 ( Figure 8 Only one is shown in the image), at least one memory 81 ( Figure 8 (Only one is shown in the image) and a computer program 82 stored in the at least one memory 81 and executable on the at least one processor 80, wherein when the processor 80 executes the computer program 82, it causes the control device 8 to perform steps S200, S300 and S700 in any of the above-described embodiments of the damage prevention control process for the cable conductor preparation process.

[0116] For example, the computer program 82 may be divided into one or more modules / units, which are stored in the memory 81 and executed by the processor 80 to complete this application. The one or more modules / units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 82 in the control device 8.

[0117] The control device 8 can be a computing device such as an industrial computer, a distributed control system, a desktop computer, a laptop, a handheld computer, or a cloud server. This control device may include, but is not limited to, a processor 80 and a memory 81. Those skilled in the art will understand that... Figure 8 This is merely an example of the control device 8 and does not constitute a limitation on the control device 8. It may include more or fewer components than shown, or combine certain components, or different components. For example, it may also include input / output devices, network access devices, buses, etc.

[0118] The processor 80 can be a Central Processing Unit (CPU), or it can be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0119] In some embodiments, the memory 81 may be an internal storage unit of the control device 8, such as a hard disk or memory of the control device 8. In other embodiments, the memory 81 may be an external storage device of the control device 8, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the control device 8. Furthermore, the memory 81 may include both internal and external storage units of the control device 8. The memory 81 is used to store the operating system, applications, bootloader, data, and other programs, such as the program code of the computer program. The memory 81 can also be used to temporarily store data that has been output or will be output.

[0120] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0121] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0122] In the embodiments provided in this application, it should be understood that the disclosed control devices and methods can be implemented in other ways. For example, the control device embodiments described above are merely illustrative. For instance, the division of modules or units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0123] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0124] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A damage prevention control process for cable conductor manufacturing, characterized in that, include: Acquire the first image of the conductor before polishing and the cumulative running time of the nylon brush wheel; Surface state feature values ​​are obtained based on the first image; wherein, the surface state feature values ​​include conductor surface roughness, oxidation degree and / or foreign matter adhesion data; The pressure compensation value caused by brush wheel wear is obtained based on the cumulative running time and the surface condition characteristic value. Adjust the contact pressure between the nylon brush wheel and the conductor according to the pressure compensation value; Obtain a second image of the conductor after polishing according to the contact pressure; If the conductor quality is determined to be acceptable based on the second image, the wrapping tension value and the current wrapping angle are obtained. The rotational speed of the first wrapping head and the first traction speed are determined based on the wrapping tension value and the current wrapping angle. After completing the wrapping according to the first wrapping head rotation speed and the first traction speed, adjust the core tension value of each core in the multi-core cable.

2. The damage prevention control process for cable conductor manufacturing as described in claim 1, characterized in that, The step of determining the first winding head rotation speed and the first traction speed based on the winding tension value and the current winding angle includes: The traction speed adjustment amount is calculated based on the deviation between the wrapping tension value and the preset tension target value. The second traction speed is obtained based on the traction speed adjustment amount; Based on the deviation between the target wrapping angle and the current wrapping angle, calculate the target ratio of the second wrapping head rotation speed to the second traction speed; Adjust the second winding head rotation speed and the second traction speed according to the target ratio to obtain the third winding head rotation speed and the third traction speed; The current overlap rate is calculated based on the rotational speed of the third wrapping head and the third traction speed. Based on the deviation between the current coverage rate and the target coverage rate, the third wrapping head rotation speed and the third traction speed are corrected to obtain the first wrapping head rotation speed and the first traction speed.

3. The damage prevention control process for cable conductor manufacturing as described in claim 1, characterized in that, The adjustment of the tension value of each core in the multi-core cable includes: The rotational speed of the virtual spindle is obtained based on the first traction speed; wherein, the virtual spindle refers to treating the multi-core cabling process as a mechanical synchronization system, introducing the virtual spindle as a unified motion reference, and each core unwinding unit as a slave axis following the virtual spindle; The unwinding motor speed of each wire core is obtained based on the rotation speed of the virtual spindle; The core tension deviation value of each core is obtained based on the core tension value. Adjust the speed of the unwinding motor corresponding to each core according to the tension deviation value of each core, thereby adjusting the tension value of each core.

4. The damage prevention control process for cable conductor manufacturing as described in claim 1, characterized in that, After determining the first winding head rotation speed and the first traction speed based on the winding tension value and the current winding angle, the process further includes: Calculate the target heating power based on the rotational speed of the first wrapping head; Adjust the current heating power according to the target heating power.

5. The damage prevention control process for cable conductor manufacturing as described in claim 4, characterized in that, The step of adjusting the current heating power according to the target heating power includes: Calculate the power correction amount based on the target heating power and the current heating power; The target heating power is added to the power correction amount to obtain the final output power; Adjust the current heating power according to the final output power.

6. The damage prevention control process for cable conductor manufacturing as described in claim 1, characterized in that, The step of obtaining the pressure compensation value caused by brush wheel wear based on the cumulative running time and the surface condition characteristic value includes: The pressure regulation coefficient is determined based on the surface state characteristic values; Based on the cumulative operating time, the corresponding pressure decay amount is retrieved from the pre-established pressure decay curve; The pressure compensation value is obtained by multiplying the pressure regulation coefficient by the pressure attenuation.

7. The damage prevention control process for cable conductor manufacturing as described in claim 1, characterized in that, Before obtaining the wrapping tension value and the current wrapping angle, the process further includes: The tension adjustment amount is calculated based on the deviation between the wrapping tension value and the preset tension range; Adjust the wrapping tension value according to the tension adjustment amount; When the wrapping tension value exceeds the preset tension range and the duration exceeds the time threshold, an early warning or shutdown signal is triggered.

8. The damage prevention control process for cable conductor manufacturing as described in claim 1, characterized in that, The step of obtaining surface state feature values ​​based on the first image includes: The root mean square value of surface undulation is extracted from the first image to obtain the surface roughness feature value; Based on the first image, extract the proportion of red components or perform threshold segmentation to obtain the oxidation degree feature value; Based on the first image, abnormal protrusions or shadow areas are identified using an edge detection algorithm to obtain foreign object attachment feature values; The surface roughness feature value, the oxidation degree feature value, and the foreign matter adhesion feature value are weighted and fused to obtain the surface state feature value.

9. The damage prevention control process for cable conductor manufacturing as described in claim 1, characterized in that, The process also includes: The surface condition of the fireproof layer of each wire core is detected online to obtain wrapping quality data; When any fireproof layer is determined to be substandard based on the wrapping quality data, the corresponding core position is recorded and an early warning or shutdown signal is triggered.

10. An environmentally friendly flexible fire-resistant cable, characterized in that, The environmentally friendly flexible fireproof cable is prepared using the process described in any one of claims 1 to 9.

Images