A tension self-adaptive adjusting mechanism of a double-wheel wire supply device

Abstract

The application relates to the technical field of tension adjustment, and discloses a tension self-adaptive adjustment mechanism of a double-wheel wire feeding device, which comprises a wire feeding device, a camera device and a control device; an initial tension setting unit determines an initial tension value of the wire feeding device based on a wire type, a winding path and a running speed; a state image acquisition unit acquires a wire state characteristic value; whether the initial tension value is adjusted is judged according to the wire state characteristic value; a tension adjustment unit determines a tension adjustment amount and acquires a target tension value based on the wire state characteristic value; and a storage unit stores the wire type, the winding path, the running speed, the tension adjustment amount and the target tension value. The application realizes accurate and intelligent adjustment of the wire feeding tension.

Description

Technical Field

[0001] This invention relates to the field of tension adjustment technology, and more specifically, to a tension adaptive adjustment mechanism for a dual-wheel wire feeding device. Background Technology

[0002] During the operation of dual-wheel wire feeding equipment, the accuracy of wire tension control directly affects product quality and production efficiency. Traditional tension adjustment mechanisms often employ preset fixed parameters or simple closed-loop feedback control methods, which are insufficient to handle complex operating conditions such as changes in wire material, fluctuations in wire diameter, and dynamic adjustments in wire feeding speed. For example, when the wire feeding speed suddenly increases, the change in inertial force on the wire may cause a momentary increase in tension. If adjustment is not timely, this can easily lead to wire stretching deformation or even breakage. Conversely, when the wire material is uneven or has joints, fixed adjustment parameters may cause significant tension fluctuations, affecting the stability of subsequent processing steps.

[0003] Therefore, it is necessary to design a tension adaptive adjustment mechanism for a dual-wheel wire feeding device to solve the problems existing in the current technology. Summary of the Invention

[0004] In view of this, the present invention proposes a tension adaptive adjustment mechanism for a dual-wheel wire feeding device, which aims to solve the problem that the tension adjustment mechanism of the traditional dual-wheel wire feeding device is difficult to adaptively cope with complex working conditions, resulting in insufficient tension control accuracy and affecting product quality and production efficiency.

[0005] This invention proposes a tension adaptive adjustment mechanism for a dual-wheel wire feeding device, comprising: The system includes a wire supply device, a camera device, and a control device; the camera device is mounted around the wire supply device; the control device is connected to the wire supply device and the camera device, and includes an initial tension setting unit, a status image acquisition unit, a tension adjustment unit, and a storage unit; wherein... The initial tension setting unit is configured to collect the wire type, the winding path of the wire supply device, and the operating speed, and determine the initial tension value of the wire supply device based on the wire type, the winding path, and the operating speed; The status image acquisition unit is configured to acquire wire image data of the wire supply device, parse the wire image data, and obtain wire status feature values; and determine whether to adjust the initial tension value based on the wire status feature values. The tension adjustment unit is configured to determine the tension adjustment amount based on the wire state characteristic value and obtain the target tension value when it is determined that the initial tension value needs to be adjusted; The storage unit is configured to store the wire type, winding path, running speed, tension adjustment amount, and target tension value.

[0006] Furthermore, when determining the initial tension value of the wire supply device based on the wire type, winding path, and operating speed, the following steps are included: A tension feature vector is constructed based on the wire type, winding path, and operating speed. The tension feature vector is compared with the historical tension vector set, and the initial tension value is determined based on the comparison result. If there exists a historical tension feature vector in the set of historical tension vectors that is the same as the tension feature vector, then the historical tension value corresponding to the historical tension feature vector is taken as the initial tension value. If there is no historical tension feature vector in the set of historical tension vectors that is the same as the tension feature vector, then all historical tension feature vectors that are the same as the winding path are selected, and a winding path feature subset is constructed. The initial tension value is determined based on the feature subset of the winding path.

[0007] Further, when determining the initial tension value based on the feature subset of the winding path, the process includes: Filter out all historical wire types that are the same as or similar to the wire type in the winding path feature subset, and extract the historical tension vector corresponding to each historical wire type to construct the wire feature subset; Calculate the similarity between each historical tension vector in the wire feature subset and the tension feature vector, and select the historical tension vector with the highest similarity as a preset number of reference vectors; The initial tension value is determined by a weighted average calculation based on the historical tension values ​​corresponding to all the reference vectors, wherein the weight of each reference vector is positively correlated with the similarity.

[0008] Furthermore, when selecting a preset number of historical tension vectors with the highest similarity as reference vectors, this includes: Determine the total number of historical tension vectors in the feature subset of the wire; If the total number is less than or equal to the preset number, then all the historical tension vectors in the feature subset of the wire are used as the reference vector; If the total number is greater than the preset number, the historical tension vectors in the feature subset of the wire are sorted from high to low similarity, and the preset number of historical tension vectors before sorting are selected as the reference vectors.

[0009] Furthermore, when parsing the wire image data and obtaining wire state feature values, the process includes: The image data of the wires acquired by the camera device is preprocessed, including image denoising, brightness correction and region cropping, to obtain an effective image of the wire supply area; Based on the effective image, the shape of the wire during the wire supply process is identified, and the contour information and position information of the wire are extracted; Based on the contour information and position information, extract state feature parameters that characterize the operating state of the wire; The state characteristic parameters are quantified to obtain the state characteristic values ​​of the wire.

[0010] Furthermore, the state characteristic parameters include one or more of the following: wire jitter amplitude, offset, and bending change characteristics.

[0011] Furthermore, when extracting state feature parameters characterizing the operating state of the wire based on the contour information and position information, the following are included: Based on the contour information, the center trajectory of the wire in the supply area is determined, and the change range of the wire center trajectory within a preset time window is calculated. The amplitude of wire jitter during the wire supply process is calculated based on the variation amplitude of the wire center trajectory. Based on the location information, the offset distance of the wire relative to the preset reference position is determined, and the offset distance is used as the offset amount of the wire; Based on the changes in wire curvature in the contour information, the bending characteristics of the wire during the wire supply process are calculated.

[0012] Furthermore, when calculating the bending change characteristics of the wire during the wire supply process based on the changes in wire curvature in the contour information, the calculation includes: Based on the contour information, the continuous contour curve of the wire within the wire supply area is extracted; The continuous contour curve is segmented to obtain multiple contour curve segments; Calculate the curvature parameters of each of the contour curve segments; Based on the preset time window, the curvature parameters corresponding to the same position are compared to obtain the curvature change. Statistical analysis of the curvature change yields the bending change characteristics of the wire during the wire supply process.

[0013] Further, when determining whether to adjust the initial tension value based on the wire condition characteristic value, the process includes: Obtain the standard value of the wire state corresponding to the wire state characteristic value; Calculate the ratio of the wire condition characteristic value to the wire condition standard value, and record it as the wire condition ratio; The wire condition ratio is compared with the wire ratio threshold, and the initial tension value is adjusted based on the comparison result. If the wire condition ratio is within the wire ratio threshold range, it is determined that no adjustment to the initial tension value is required. If the wire condition ratio exceeds the wire ratio threshold range, it is determined that the initial tension value needs to be adjusted.

[0014] Further, when determining the tension adjustment amount based on the wire state characteristic values ​​and obtaining the target tension value, the process includes: Calculate the difference between the center value of the wire condition ratio and the wire condition threshold, and record it as the wire condition difference; The wire condition difference is compared with the first wire condition difference and the second wire condition difference, and the tension adjustment amount is determined based on the comparison result; wherein the first wire condition difference is less than the second wire condition difference; When the wire condition difference is less than or equal to the first wire condition difference, the tension adjustment amount is determined to be the first tension adjustment amount; When the difference in wire condition is greater than the difference in the first wire condition and less than or equal to the difference in the second wire condition, the tension adjustment amount is determined to be the second tension adjustment amount. When the difference in the condition of the wire is greater than the difference in the condition of the second wire, the tension adjustment amount is determined to be the third tension adjustment amount.

[0015] Compared with existing technologies, the advantages of this invention are as follows: The tension adaptive adjustment mechanism of the dual-wheel wire feeding device provided by this invention acquires real-time images of the wire's operating status using a camera device. Combined with the collaborative work of the initial tension setting unit, the status image acquisition unit, and the tension adjustment unit in the control device, it achieves precise and intelligent adjustment of the wire feeding tension. The initial tension setting unit, based on multi-dimensional parameters such as wire type, winding path, and operating speed, and combined with historical data comparison and weighted calculation, can provide scientifically reasonable initial tension values ​​for the wire feeding process under different working conditions, avoiding the subjectivity and errors of traditional experience-based settings. The status image acquisition unit, through preprocessing, morphological recognition, and feature parameter extraction of the wire image data, can accurately capture key status information such as the wire's jitter amplitude, offset, and bending change characteristics, providing a reliable basis for tension adjustment. The tension adjustment unit, based on the degree of deviation between the wire's status characteristic values ​​and the standard values, determines different tension adjustment amounts in stages, achieving refined dynamic adjustment of the tension. This design not only effectively avoids problems such as wire stretching deformation and breakage caused by excessive tension, or wire loosening and tangling caused by insufficient tension, but also significantly improves the stability and reliability of the wire supply process, ensuring the quality of the wire products. At the same time, the storage unit's recording of various parameters and adjustment data provides valuable data support for subsequent process optimization, equipment maintenance, and tension parameter setting under similar working conditions, thus improving the overall automation level and production efficiency of the dual-wheel wire supply equipment. Attached Figure Description

[0016] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 The diagram shows the structure of the tension adaptive adjustment mechanism of the dual-wheel wire feeding device provided in this embodiment of the invention. Detailed Implementation

[0017] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specified, embodiments and features in the embodiments of the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0018] See Figure 1As shown in some embodiments of this application, this embodiment provides a tension adaptive adjustment mechanism for a dual-wheel wire feeding device, including: The system includes a wire supply device, a camera device, and a control device; the camera device is mounted around the wire supply device; the control device is connected to the wire supply device and the camera device, and includes an initial tension setting unit, a status image acquisition unit, a tension adjustment unit, and a storage unit; wherein... The initial tension setting unit is configured to collect the wire type, the winding path of the wire supply device, and the operating speed, and determine the initial tension value of the wire supply device based on the wire type, the winding path, and the operating speed; The status image acquisition unit is configured to acquire wire image data of the wire supply device, parse the wire image data, and obtain wire status feature values; and determine whether to adjust the initial tension value based on the wire status feature values. The tension adjustment unit is configured to determine the tension adjustment amount based on the wire state characteristic value and obtain the target tension value when it is determined that the initial tension value needs to be adjusted; The storage unit is configured to store the wire type, winding path, running speed, tension adjustment amount, and target tension value.

[0019] In this embodiment, the wire supply device is the wire supply device for a double twisting machine as described in the patent (application number 202210165991.3).

[0020] It is understood that the tension adaptive adjustment mechanism of the dual-wheel wire feeding device provided in this embodiment acquires real-time images of the wire's operating status using a camera device. Combined with the collaborative work of the initial tension setting unit, the status image acquisition unit, and the tension adjustment unit in the control device, it achieves precise and intelligent adjustment of the wire feeding tension. The initial tension setting unit, based on multi-dimensional parameters such as wire type, winding path, and operating speed, and combined with historical data comparison and weighted calculation, can provide scientifically reasonable initial tension values ​​for the wire feeding process under different working conditions, avoiding the subjectivity and errors of traditional experience-based settings. The status image acquisition unit, through preprocessing, morphological recognition, and feature parameter extraction of the wire image data, can accurately capture key status information such as the wire's jitter amplitude, offset, and bending change characteristics, providing a reliable basis for tension adjustment. The tension adjustment unit, based on the degree of deviation between the wire's status characteristic values ​​and the standard values, determines different tension adjustment amounts in stages, achieving refined dynamic adjustment of the tension. This design not only effectively avoids problems such as wire stretching deformation and breakage caused by excessive tension, or wire loosening and tangling caused by insufficient tension, but also significantly improves the stability and reliability of the wire supply process, ensuring the quality of the wire products. At the same time, the storage unit's recording of various parameters and adjustment data provides valuable data support for subsequent process optimization, equipment maintenance, and tension parameter setting under similar working conditions, thus improving the overall automation level and production efficiency of the dual-wheel wire supply equipment.

[0021] Specifically, determining the initial tension value of the wire supply device based on the wire type, winding path, and operating speed includes: A tension feature vector is constructed based on the wire type, winding path, and operating speed. The tension feature vector is compared with the historical tension vector set, and the initial tension value is determined based on the comparison result. If there exists a historical tension feature vector in the set of historical tension vectors that is the same as the tension feature vector, then the historical tension value corresponding to the historical tension feature vector is taken as the initial tension value. If there is no historical tension feature vector in the set of historical tension vectors that is the same as the tension feature vector, then all historical tension feature vectors that are the same as the winding path are selected, and a winding path feature subset is constructed. The initial tension value is determined based on the feature subset of the winding path.

[0022] Understandably, this method of determining initial tension values ​​based on historical data comparison can fully utilize the effective experience accumulated in past production processes. When encountering operating conditions that are completely consistent with history (i.e., the wire type, winding path, and operating speed are all the same), directly reusing historical tension values ​​can ensure the accuracy and reliability of the initial settings and avoid repeated adjustments. However, when there is no completely matching historical data, a subset is constructed by prioritizing the selection of historical tension feature vectors with the same winding path. This is because the winding path has a significant impact on the friction, number of bends, and guiding method of the wire during the supply process, and is one of the key factors determining the tension requirements.

[0023] Specifically, determining the initial tension value based on the subset of winding path features includes: Filter out all historical wire types that are the same as or similar to the wire type in the winding path feature subset, and extract the historical tension vector corresponding to each historical wire type to construct the wire feature subset; Calculate the similarity between each historical tension vector in the wire feature subset and the tension feature vector, and select the historical tension vector with the highest similarity as a preset number of reference vectors; The initial tension value is determined by a weighted average calculation based on the historical tension values ​​corresponding to all the reference vectors, wherein the weight of each reference vector is positively correlated with the similarity.

[0024] In this embodiment, in the field of metal wires, copper-clad steel wire and copper alloy wire can be considered similar types of wires. Both use metal as the base material, have good conductivity and certain mechanical strength, and their sensitivity to tension during wire supply is quite similar. Polyurethane enameled wire and polyester enameled wire, despite slight differences in their coating materials, are both insulated coated metal wires with similar physical properties such as wire diameter and flexibility, and can be classified as similar wire types. In non-metallic wires, nylon wire and polyester wire are both synthetic fiber wires with high tensile strength and abrasion resistance, and their tension requirements during wire supply are somewhat common. While single-mode fiber and multimode fiber in optical fiber cables have different transmission performances, as glass fiber materials, their brittleness and the need for precise tension control are similar, making them typical examples of similar wire types. These wire types have a high degree of similarity in material properties, physical parameters, or application scenarios; therefore, their historical tension data can be referenced when setting the initial tension value during tension adjustment.

[0025] Understandably, the similarity is calculated using a cosine similarity algorithm. The specific steps are as follows: both the tension feature vector and each historical tension vector are represented as n-dimensional vectors, where n is the dimension of the parameters constituting the tension feature vector (such as wire diameter, elastic modulus, operating speed, etc.). The similarity is measured by calculating the cosine of the angle between the two vectors. The cosine similarity value ranges from -1 to 1; the closer the value is to 1, the more similar the directions of the two vectors are, meaning the corresponding operating conditions are more similar. For example, when the tension feature vector is (0.8mm, 200GPa, 15m / s) and a historical tension vector is (0.78mm, 195GPa, 14.8m / s), the cosine similarity formula shows a high similarity, indicating that the wire tension requirements under these two operating conditions are highly relevant in actual wire supply processes. After calculating the similarity between each historical tension vector and the current tension feature vector using this method, the top 5 historical tension vectors with the highest similarity are selected as reference vectors. Weights are then assigned to each reference vector based on its similarity value (e.g., the reference vector with the highest similarity has a weight of 0.3, the next highest 0.25, and so on). Finally, the historical tension values ​​corresponding to these reference vectors are weighted and summed to obtain the final initial tension value. This weighted average calculation method based on cosine similarity can fully utilize empirical data from similar working conditions when completely matching historical data is lacking, making the initial tension value setting more scientific and reasonable, and effectively reducing tension setting deviations caused by parameter differences.

[0026] Specifically, when selecting a preset number of historical tension vectors with the highest similarity as reference vectors, the following applies: Determine the total number of historical tension vectors in the feature subset of the wire; If the total number is less than or equal to the preset number, then all the historical tension vectors in the feature subset of the wire are used as the reference vector; If the total number is greater than the preset number, the historical tension vectors in the feature subset of the wire are sorted from high to low similarity, and the preset number of historical tension vectors before sorting are selected as the reference vectors.

[0027] Understandably, this flexible approach to the number of reference vectors ensures reliable reference data regardless of the amount of data. When the number of historical tension vectors in the wire feature subset is small (e.g., less than or equal to a preset 5), all vectors are used as references, maximizing the use of limited similar data and avoiding initial tension value calculation errors due to insufficient sample size. Conversely, when historical data is abundant (total number greater than the preset number), selecting the top preset number of vectors by similarity ranking ensures high-quality reference data (highest similarity) while controlling computational load and improving the efficiency of initial tension value determination. For example, if there are 20 historical tension vectors in the wire feature subset, after calculating and ranking them using cosine similarity, selecting the top 5 vectors with the highest similarity for weighted averaging ensures computational accuracy while avoiding interference from too many low-similarity vectors, making the initial tension value setting more precise and efficient.

[0028] Specifically, parsing the wire image data and obtaining wire state feature values ​​includes: The image data of the wires acquired by the camera device is preprocessed, including image denoising, brightness correction and region cropping, to obtain an effective image of the wire supply area; Based on the effective image, the shape of the wire during the wire supply process is identified, and the contour information and position information of the wire are extracted; Based on the contour information and position information, extract state feature parameters that characterize the operating state of the wire; The state characteristic parameters are quantified to obtain the state characteristic values ​​of the wire.

[0029] Specifically, the state characteristic parameters include one or more of the following: wire jitter amplitude, offset, and bending change characteristics.

[0030] Specifically, when extracting state feature parameters characterizing the operating state of the wire based on the contour information and position information, the following are included: Based on the contour information, the center trajectory of the wire in the supply area is determined, and the change range of the wire center trajectory within a preset time window is calculated. The amplitude of wire jitter during the wire supply process is calculated based on the variation amplitude of the wire center trajectory. Based on the location information, the offset distance of the wire relative to the preset reference position is determined, and the offset distance is used as the offset amount of the wire; Based on the changes in wire curvature in the contour information, the bending characteristics of the wire during the wire supply process are calculated.

[0031] Understandably, this wire image data analysis process, through a series of progressive processing steps, achieves precise quantification of the wire's operating status. First, the image preprocessing stage provides high-quality, effective images for subsequent shape recognition by employing noise reduction (e.g., using Gaussian filtering to remove random noise introduced during camera acquisition), brightness correction (adjusting image brightness consistency under different lighting conditions through histogram equalization), and region cropping (preserving the core area of ​​the wire's operation while eliminating irrelevant background interference). Next, the shape recognition stage uses edge detection algorithms (such as the Canny operator) to extract the wire's contour information and determines the wire's real-time position in the image through feature point matching, laying the foundation for extracting state feature parameters. In the extraction of state feature parameters, determining the center trajectory is crucial. By fitting the center point of the wire profile in consecutive frame images, its motion trajectory is obtained. Then, the maximum deviation range of the trajectory within a preset time window (e.g., 1 second) is calculated, which can be quantified as jitter amplitude. Offset is obtained by comparing the current center position of the wire with a preset standard reference position (e.g., the theoretical center line of the wire supply path), yielding the lateral and longitudinal offset distances. Bending change features are characterized by analyzing the frequency and amplitude of curvature value changes at various points on the profile. For example, when the wire undergoes abnormal bending, the local curvature will increase significantly. Finally, these parameters (jitter amplitude, offset, and bending change features) are quantified according to preset dimension conversion rules (e.g., converting pixel units to the actual physical unit millimeters) to obtain specific numerical wire state feature values, providing an objective and comparable basis for subsequent tension adjustment judgments.

[0032] Specifically, when calculating the bending change characteristics of the wire during the wire supply process based on the changes in wire curvature in the contour information, the following steps are included: Based on the contour information, the continuous contour curve of the wire within the wire supply area is extracted; The continuous contour curve is segmented to obtain multiple contour curve segments; Calculate the curvature parameters of each of the contour curve segments; Based on the preset time window, the curvature parameters corresponding to the same position are compared to obtain the curvature change. Statistical analysis of the curvature change yields the bending change characteristics of the wire during the wire supply process.

[0033] Understandably, after the continuous profile curve of the wire captured by the camera is segmented, the profile curve segment of a certain wire supply area is divided into 5 segments. At time t1, the curvature parameters of each segment are 0.02 / mm, 0.03 / mm, 0.015 / mm, 0.025 / mm, and 0.018 / mm, respectively. At time t2, after a preset time window, the curvature parameters of the 5 profile curve segments at the same location become 0.022 / mm, 0.045 / mm, 0.016 / mm, 0.028 / mm, and 0.020 / mm, respectively. By calculating the difference in curvature parameters of each segment at the same location between time t2 and t1, the curvature changes are obtained as 0.002 / mm, 0.015 / mm, 0.001 / mm, 0.003 / mm, and 0.002 / mm, respectively. Statistical analysis was performed on these curvature changes, for example, calculating their average value as 0.0046 / mm, maximum value as 0.015 / mm, and variance as 0.0000324 / mm. 2 These statistical results together constitute the bending change characteristics of the wire during the wire supply process during this period.

[0034] Specifically, determining whether to adjust the initial tension value based on the wire condition characteristic value includes: Obtain the standard value of the wire state corresponding to the wire state characteristic value; Calculate the ratio of the wire condition characteristic value to the wire condition standard value, and record it as the wire condition ratio; The wire condition ratio is compared with the wire ratio threshold, and the initial tension value is adjusted based on the comparison result. If the wire condition ratio is within the wire ratio threshold range, it is determined that no adjustment to the initial tension value is required. If the wire condition ratio exceeds the wire ratio threshold range, it is determined that the initial tension value needs to be adjusted.

[0035] In this embodiment, the wire state characteristic value is preferably an offset.

[0036] Understandably, when using offset as the criterion, the standard value for wire condition is the preset maximum allowable offset. For example, in a precision electronic wire supply scenario, this standard value can be set to 0.5mm. The wire condition ratio is the ratio of the current actual offset to 0.5mm, and the threshold range for the wire ratio is usually set to [0.8, 1.2]. When the actual offset is 0.45mm, the wire condition ratio is 0.45 / 0.5=0.9, which is within the range of [0.8, 1.2], indicating that the wire is running stably and no adjustment to the initial tension value is needed. If the actual offset increases to 0.65mm, the ratio is 0.65 / 0.5=1.3, exceeding the upper limit of the threshold, indicating that the tension may be too low, causing the wire to shake more, and tension adjustment is required. When the offset decreases to 0.35mm, the ratio is 0.35 / 0.5=0.7, which is below the lower limit of the threshold, it may be that the tension is too high, causing the wire to be overly taut, and adjustment is also required. This ratio-based judgment method can unify the state characteristic values ​​of different wire types and different wire supply accuracy requirements into a relative quantity comparison dimension, which enhances the universality and flexibility of the judgment standard and avoids absolute value judgment errors caused by differences in wire specifications.

[0037] Specifically, when determining the tension adjustment amount based on the wire condition characteristic values ​​and obtaining the target tension value, the process includes: Calculate the difference between the center value of the wire condition ratio and the wire condition threshold, and record it as the wire condition difference; The wire condition difference is compared with the first wire condition difference and the second wire condition difference, and the tension adjustment amount is determined based on the comparison result; wherein the first wire condition difference is less than the second wire condition difference; When the wire condition difference is less than or equal to the first wire condition difference, the tension adjustment amount is determined to be the first tension adjustment amount; When the difference in wire condition is greater than the difference in the first wire condition and less than or equal to the difference in the second wire condition, the tension adjustment amount is determined to be the second tension adjustment amount. When the difference in the condition of the wire is greater than the difference in the condition of the second wire, the tension adjustment amount is determined to be the third tension adjustment amount.

[0038] Understandably, taking offset as an example, if the wire ratio threshold range is [0.8, 1.2], its center value is 1.0. The wire state difference is the difference between the current wire state ratio and 1.0. Assume the first wire state difference is set to -0.1 and 0.1 (i.e., the ratio is between 0.9 and 1.1), and the second wire state difference is set to -0.2 and 0.2 (i.e., the ratio is between 0.8 and 0.9 and between 1.1 and 1.2). When the wire condition difference is 0.05 (corresponding to a ratio of 1.05), which is less than the first wire condition difference of 0.1, the tension adjustment amount is determined as the first tension adjustment amount (e.g., fine adjustment + 0.5N). If the wire condition difference is 0.15 (corresponding to a ratio of 1.15), which is greater than the first wire condition difference of 0.1 and less than the second wire condition difference of 0.2, it is determined as the second tension adjustment amount (e.g., medium adjustment + 1.0N). If the wire condition difference is 0.25 (corresponding to a ratio of 1.25), which is greater than the second wire condition difference of 0.2, it is determined as the third tension adjustment amount (e.g., large adjustment + 1.5N). Similarly, when the difference is negative (e.g., -0.08 corresponding to a ratio of 0.92), the corresponding negative adjustment amount is determined according to the above rules (e.g., the first tension adjustment amount -0.5N). By setting adjustment amounts in stages, the tension can be adjusted in a gradient according to the degree to which the wire deviates from the standard. This avoids tension fluctuations caused by excessive adjustment or untimely adjustments caused by insufficient adjustment, making tension adjustment more precise and stable. The target tension value is the sum (or difference) of the initial tension value and the determined tension adjustment amount. For example, if the initial tension value is 10N and the tension adjustment amount is +1.0N, the target tension value is 11N.

[0039] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program goods. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program goods on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0040] This application is described with flowcharts and / or block diagrams of methods, apparatus (systems), and computer program goods according to embodiments of this application. It will be understood that each block of the flowcharts and / or block diagrams, and combinations of blocks in the flowcharts and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowcharts and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1A device that provides the functions specified in one or more boxes.

[0041] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0042] These computer program instructions can also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A tension adaptive adjustment mechanism for a dual-wheel wire feeding device, characterized in that, include: Line supply equipment, camera equipment, and control devices; The camera equipment is mounted around the periphery of the power supply equipment; The control device is connected to the wire supply equipment and the camera equipment. The control device includes an initial tension setting unit, a status image acquisition unit, a tension adjustment unit, and a storage unit. The initial tension setting unit is configured to collect the wire type, the winding path of the wire supply device, and the operating speed, and determine the initial tension value of the wire supply device based on the wire type, the winding path, and the operating speed; The status image acquisition unit is configured to acquire wire image data of the wire supply device, parse the wire image data, and obtain wire status feature values; and determine whether to adjust the initial tension value based on the wire status feature values. The tension adjustment unit is configured to determine the tension adjustment amount based on the wire state characteristic value and obtain the target tension value when it is determined that the initial tension value needs to be adjusted; The storage unit is configured to store the wire type, winding path, running speed, tension adjustment amount, and target tension value.

2. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 1, characterized in that, Determining the initial tension value of the wire supply device based on the wire type, winding path, and operating speed includes: A tension feature vector is constructed based on the wire type, winding path, and operating speed. The tension feature vector is compared with the historical tension vector set, and the initial tension value is determined based on the comparison result. If there exists a historical tension feature vector in the set of historical tension vectors that is the same as the tension feature vector, then the historical tension value corresponding to the historical tension feature vector is taken as the initial tension value. If there is no historical tension feature vector in the set of historical tension vectors that is the same as the tension feature vector, then all historical tension feature vectors that are the same as the winding path are selected, and a winding path feature subset is constructed. The initial tension value is determined based on the feature subset of the winding path.

3. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 2, characterized in that, Determining the initial tension value based on the feature subset of the winding path includes: Filter out all historical wire types that are the same as or similar to the wire type in the winding path feature subset, and extract the historical tension vector corresponding to each historical wire type to construct the wire feature subset; Calculate the similarity between each historical tension vector in the wire feature subset and the tension feature vector, and select the historical tension vector with the highest similarity as a preset number of reference vectors; The initial tension value is determined by a weighted average calculation based on the historical tension values ​​corresponding to all the reference vectors, wherein the weight of each reference vector is positively correlated with the similarity.

4. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 3, characterized in that, When selecting a preset number of historical tension vectors with the highest similarity as reference vectors, the following are included: Determine the total number of historical tension vectors in the feature subset of the wire; If the total number is less than or equal to the preset number, then all the historical tension vectors in the feature subset of the wire are used as the reference vector; If the total number is greater than the preset number, the historical tension vectors in the feature subset of the wire are sorted from high to low similarity, and the preset number of historical tension vectors before sorting are selected as the reference vectors.

5. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 4, characterized in that, When parsing the wire image data and obtaining the wire state feature values, the process includes: The image data of the wires acquired by the camera device is preprocessed, including image denoising, brightness correction and region cropping, to obtain an effective image of the wire supply area; Based on the effective image, the shape of the wire during the wire supply process is identified, and the contour information and position information of the wire are extracted; Based on the contour information and position information, extract state feature parameters that characterize the operating state of the wire; The state characteristic parameters are quantified to obtain the state characteristic values ​​of the wire.

6. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 5, characterized in that, The state characteristic parameters include one or more of the following: wire jitter amplitude, offset, and bending change characteristics.

7. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 6, characterized in that, When extracting state feature parameters characterizing the operating state of the wire based on the contour information and position information, the following are included: Based on the contour information, the center trajectory of the wire in the supply area is determined, and the change range of the wire center trajectory within a preset time window is calculated. The amplitude of wire jitter during the wire supply process is calculated based on the variation amplitude of the wire center trajectory. Based on the location information, the offset distance of the wire relative to the preset reference position is determined, and the offset distance is used as the offset amount of the wire; Based on the changes in wire curvature in the contour information, the bending characteristics of the wire during the wire supply process are calculated.

8. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 7, characterized in that, When calculating the bending change characteristics of the wire during the wire supply process based on the changes in wire curvature in the contour information, the following steps are included: Based on the contour information, the continuous contour curve of the wire within the wire supply area is extracted; The continuous contour curve is segmented to obtain multiple contour curve segments; Calculate the curvature parameters of each of the contour curve segments; Based on the preset time window, the curvature parameters corresponding to the same position are compared to obtain the curvature change. Statistical analysis of the curvature change yields the bending change characteristics of the wire during the wire supply process.

9. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 8, characterized in that, When determining whether to adjust the initial tension value based on the wire condition characteristic value, the following steps are included: Obtain the standard value of the wire state corresponding to the wire state characteristic value; Calculate the ratio of the wire condition characteristic value to the wire condition standard value, and record it as the wire condition ratio; The wire condition ratio is compared with the wire ratio threshold, and the initial tension value is adjusted based on the comparison result. If the wire condition ratio is within the wire ratio threshold range, it is determined that no adjustment to the initial tension value is required. If the wire condition ratio exceeds the wire ratio threshold range, it is determined that the initial tension value needs to be adjusted.

10. The tension adaptive adjustment mechanism of the dual-wheel wire feeding device according to claim 9, characterized in that, When determining the tension adjustment amount based on the wire condition characteristic values ​​and obtaining the target tension value, the process includes: Calculate the difference between the center value of the wire condition ratio and the wire condition threshold, and record it as the wire condition difference; The wire condition difference is compared with the first wire condition difference and the second wire condition difference, and the tension adjustment amount is determined based on the comparison result; wherein the first wire condition difference is less than the second wire condition difference; When the wire condition difference is less than or equal to the first wire condition difference, the tension adjustment amount is determined to be the first tension adjustment amount; When the difference in wire condition is greater than the difference in the first wire condition and less than or equal to the difference in the second wire condition, the tension adjustment amount is determined to be the second tension adjustment amount. When the difference in the condition of the wire is greater than the difference in the condition of the second wire, the tension adjustment amount is determined to be the third tension adjustment amount.

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