Method, apparatus and equipment for combined control of preheating temperature of copper-clad aluminum wire

Abstract

This application relates to the field of copper-clad aluminum wire production technology, and particularly to a method, apparatus, and equipment for composite control of copper-clad aluminum wire cladding preheating temperature. The method includes: acquiring real-time operating data; generating dynamic control parameters based on the real-time operating data; obtaining a first compensation factor based on the current segment temperature; obtaining a second compensation factor based on the ambient temperature; obtaining a third compensation factor based on the contact resistance; obtaining a fourth compensation factor based on the wire speed; fusing the first, second, third, and fourth compensation factors to obtain a comprehensive compensation factor; and adjusting the dynamic control parameters based on the comprehensive compensation factor. Therefore, the copper-clad aluminum wire cladding preheating temperature composite control method provided by this application can solve the problem of maintaining a stable and uniform preheating temperature under multiple changing operating conditions.

Description

Technical Field

[0001] This application belongs to the field of copper-clad aluminum wire production technology, and particularly relates to a method, apparatus and equipment for composite control of copper-clad aluminum wire cladding preheating temperature. Background Technology

[0002] Existing copper-clad aluminum wire production technology mainly adopts the cladding welding method. Its core process is to longitudinally wrap copper strips onto the surface of aluminum core and then weld them to form a continuous cladding layer. The copper-clad aluminum wire cladding preheating technology mostly adopts a fixed power output or a simple PID control method based on a single variable (such as temperature feedback). Its control logic is relatively fixed and usually operates with preset constant heating parameters.

[0003] Existing technologies, due to fixed operating conditions (such as fixed power), cannot adapt to changes in speed, environment, etc., and cannot adjust heating power in a timely manner, resulting in large temperature fluctuations in the aluminum core and stress concentration in the cladding layer. Simultaneously, changes in ambient temperature and airflow velocity affect the convective heat dissipation efficiency of the equipment surface, and traditional technologies do not incorporate environmental heat loss into their compensation models, leading to a severe mismatch between heating power and actual heat dissipation conditions. Furthermore, heating elements experience a decline in heating efficiency after long-term use, further exacerbating the discrepancy between actual heating power and theoretical requirements. More importantly, traditional technologies lack proactive control over temperature field uniformity, easily leading to unreasonable temperature gradients and the coexistence of localized overheating or underheating. The combined effect of these multiple factors results in large fluctuations in the aluminum core preheating temperature and uneven temperature field distribution, which in turn causes quality problems during the copper-clad aluminum wire cladding welding process, such as insufficient interfacial bonding strength, stress concentration in the cladding layer, peeling, or cracking, severely restricting product consistency and production qualification rates. Therefore, existing technologies suffer from the problem of difficulty in maintaining a stable and uniform preheating temperature under varying operating conditions. Summary of the Invention

[0004] This application provides a method, apparatus, and equipment for combined control of preheating temperature for copper-clad aluminum wire coating, which can solve the problem of difficulty in maintaining a stable and uniform preheating temperature under various operating conditions.

[0005] In a first aspect, embodiments of this application provide a method for combined control of the preheating temperature of copper-clad aluminum wire, including: Acquire real-time operating condition data; wherein, the real-time operating condition data includes wire speed, current segment temperature, ambient temperature, and contact resistance; Dynamic control parameters are generated based on the real-time operating data; wherein, the dynamic control parameters refer to parameters that control the output power. A first compensation factor is obtained based on the current segment temperature; wherein, the first compensation factor is used to reflect the compensation of control parameters required for the heating element due to aging or efficiency degradation; A second compensation factor is obtained based on the ambient temperature; wherein, the second compensation factor is used to reflect the control parameter compensation required to reflect the heat loss caused by the ambient heat dissipation conditions; A third compensation factor is obtained based on the contact resistance; wherein, the third compensation factor is used to reflect the control parameter compensation required to reflect the energy loss caused by the contact resistance; A fourth compensation factor is obtained based on the wire speed; wherein, the fourth compensation factor is used to compensate for the control parameters required to reflect the changes in heating demand caused by changes in wire speed; The first compensation factor, the second compensation factor, the third compensation factor, and the fourth compensation factor are fused together to obtain a comprehensive compensation factor; The dynamic control parameters are adjusted based on the comprehensive compensation factor.

[0006] The technical solutions described in this application embodiment have at least the following technical effects: The copper-clad aluminum wire preheating temperature composite control method provided in this application acquires real-time operating data; generates dynamic control parameters based on the real-time operating data; obtains a first compensation factor based on the current segment temperature; obtains a second compensation factor based on the ambient temperature; obtains a third compensation factor based on the contact resistance; obtains a fourth compensation factor based on the wire speed; merges the first, second, third, and fourth compensation factors to obtain a comprehensive compensation factor; and adjusts the dynamic control parameters based on the comprehensive compensation factor. Therefore, the copper-clad aluminum wire preheating temperature composite control method provided in this application completely decouples the four physical mechanisms of heating element aging, ambient heat dissipation fluctuations, contact resistance loss, and wire speed changes, establishing independent compensation factors for each, and then using a fusion algorithm for synergistic action, which is beneficial for achieving accurate fitting of the total heat demand. By uniformly scheduling power and frequency through the comprehensive compensation factor, the two are adjusted synergistically, which is beneficial for optimizing energy transmission efficiency and equipment operating status while meeting heat demand. Traditional temperature control systems typically use PID control based on temperature deviation, which mixes component aging, environmental heat dissipation, contact loss, and speed fluctuations into a single error signal. This makes it impossible to distinguish the source of disturbance, resulting in poorly targeted compensation actions and a tendency to overcompensate or undercompensate. This application establishes four independent physical compensation factors, achieving decoupled identification and targeted compensation of disturbance sources. This helps solve the problem of maintaining a stable and uniform preheating temperature under varying operating conditions.

[0007] In one possible implementation of the first aspect, obtaining the first compensation factor based on the current segment temperature includes: Determine the heating time required to reach the target temperature based on the current segment temperature; The rate of decrease in the current heating efficiency of the heating element relative to its initial heating efficiency is determined based on the heating time. The first compensation factor is calculated based on the attenuation ratio.

[0008] In one possible implementation of the first aspect, obtaining the second compensation factor based on the ambient temperature includes: The heat loss power is obtained based on the ambient temperature; wherein, the heat loss power refers to the heat power lost by the preheating equipment to the surrounding environment under the current environmental conditions; The heat loss increment is obtained based on the heat loss power. The second compensation factor is calculated based on the heat loss increment.

[0009] In one possible implementation of the first aspect, obtaining the third compensation factor based on the contact resistance includes: If the contact resistance is greater than a preset contact resistance threshold, the degree of contact loss is calculated based on the contact resistance. The third compensation factor is calculated based on the degree of contact loss.

[0010] In one possible implementation of the first aspect, obtaining the fourth compensation factor based on the wire speed includes: The heating requirement per unit time is determined based on the wire speed; Calculate the heating power required to reach the target temperature based on the heating requirements; The fourth compensation factor is calculated based on the ratio of the heating power to the reference power.

[0011] In one possible implementation of the first aspect, the method further includes: The rate of temperature change along the length direction is determined based on the wire speed. Determine the maximum allowable temperature deviation range based on the target temperature; The temperature gradient threshold is adjusted based on the rate of temperature change and the maximum temperature deviation range.

[0012] In one possible implementation of the first aspect, generating dynamic control parameters based on the real-time operating data includes: The temperature control zone is divided in real time based on the real-time operating data; wherein the temperature control zone includes a heating zone, a transition zone, and a stabilization zone; The temperature gradient of the temperature control region is calculated using the central difference method. The dynamic control parameters are calculated based on the temperature gradient.

[0013] In one possible implementation of the first aspect, calculating the dynamic control parameters based on the temperature gradient includes: The temperature gradient difference between adjacent sub-regions in the temperature control region is determined based on the temperature gradient. If the temperature gradient difference is greater than the temperature gradient threshold, the distribution ratio of heating power in adjacent sub-regions in the temperature control area is adjusted according to the temperature gradient difference. The dynamic control parameters are determined based on the allocation ratio.

[0014] Secondly, embodiments of this application provide a composite control device for the preheating temperature of copper-clad aluminum wire, comprising: The acquisition module is used to acquire real-time operating condition data; wherein, the real-time operating condition data includes wire speed, current segment temperature, ambient temperature, and contact resistance; The dynamic control parameter module is used to generate dynamic control parameters based on the real-time operating data; wherein, the dynamic control parameters refer to parameters for controlling the output power; The first compensation factor module is used to obtain a first compensation factor based on the current segment temperature; wherein, the first compensation factor is used to reflect the control parameter compensation required for the heating element due to aging or efficiency decay. The second compensation factor module is used to obtain a second compensation factor based on the ambient temperature; wherein, the second compensation factor is used to reflect the control parameter compensation required to reflect the heat loss caused by the ambient heat dissipation conditions. The third compensation factor module is used to obtain a third compensation factor based on the contact resistance; wherein the third compensation factor is used to reflect the control parameter compensation required to reflect the energy loss caused by the contact resistance. The fourth compensation factor module is used to obtain a fourth compensation factor based on the wire speed; wherein, the fourth compensation factor is used to reflect the control parameter compensation required to reflect the change in heating demand caused by the change in wire speed; The comprehensive compensation factor module is used to fuse the first compensation factor, the second compensation factor, the third compensation factor and the fourth compensation factor to obtain a comprehensive compensation factor; The adjustment module is used to adjust the dynamic control parameters according to the comprehensive compensation factor.

[0015] Thirdly, embodiments of this application provide a preheating temperature control device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the method as described in any one of the first aspects above.

[0016] Fourthly, embodiments of this application provide a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any of the first aspects above.

[0017] Fifthly, embodiments of this application provide a computer program product that, when running on a preheating temperature control device, causes the preheating temperature control device to perform the method described in any one of the first aspects above.

[0018] It is understood that the beneficial effects of the second to fifth 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

[0019] 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.

[0020] Figure 1 This is a schematic flowchart of a copper-clad aluminum wire preheating temperature composite control method provided in an embodiment of this application; Figure 2 This is a schematic diagram of the implementation process of steps S300, S400, S500 and S600 in the copper-clad aluminum wire preheating temperature composite control method provided in an embodiment of this application. Figure 3 This is a schematic diagram of the implementation process of steps S200 and S230 in the copper-clad aluminum wire preheating temperature composite control method provided in an embodiment of this application; Figure 4 This is a schematic diagram of the compensation factor in the copper-clad aluminum wire preheating temperature composite control method provided in an embodiment of this application; Figure 5 This is a schematic diagram of the temperature gradient in a copper-clad aluminum wire preheating temperature composite control method provided in an embodiment of this application; Figure 6 This is a schematic diagram of the composite control device for preheating temperature of copper-clad aluminum wire provided in the embodiments of this application; Figure 7 This is a schematic diagram of the preheating temperature control device provided in the embodiments of this application. Detailed Implementation

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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 phrase "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]."

[0025] 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.

[0026] 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.

[0027] In related technologies, due to fixed operating conditions (such as fixed power), the technology cannot adapt to changes in speed, environment, etc., and cannot adjust the heating power in a timely manner, resulting in large temperature fluctuations in the aluminum core and stress concentration in the cladding layer. Simultaneously, changes in ambient temperature and airflow velocity affect the convective heat dissipation efficiency of the equipment surface, and traditional technologies do not incorporate environmental heat loss into the compensation model, leading to a severe mismatch between heating power and actual heat dissipation conditions. Furthermore, heating elements experience a decline in heating efficiency after long-term use, further exacerbating the deviation between actual heating power and theoretical requirements. More importantly, traditional technologies lack active control over the uniformity of the temperature field, easily leading to unreasonable temperature gradients and the coexistence of localized overheating or underheating. The result of the coupled effect of these multiple factors is: large fluctuations in the preheating temperature of the aluminum core and uneven temperature field distribution, which in turn causes quality problems such as insufficient interfacial bonding strength, stress concentration in the cladding layer, peeling, or cracking during the cladding welding process of the copper-clad aluminum wire, severely restricting product consistency and production qualification rate. Therefore, existing technologies suffer from the problem of difficulty in maintaining a stable and uniform preheating temperature under varying operating conditions.

[0028] To address the aforementioned issues, this application provides a method, apparatus, and device for composite control of copper-clad aluminum wire preheating temperature. The method involves acquiring real-time operating data; generating dynamic control parameters based on the real-time operating data; obtaining a first compensation factor based on the current segment temperature; obtaining a second compensation factor based on the ambient temperature; obtaining a third compensation factor based on contact resistance; obtaining a fourth compensation factor based on wire speed; fusing the first, second, third, and fourth compensation factors to obtain a comprehensive compensation factor; and adjusting the dynamic control parameters based on the comprehensive compensation factor. Therefore, the copper-clad aluminum wire preheating temperature composite control method provided in this application completely decouples the four physical mechanisms of heating element aging, ambient heat dissipation fluctuations, contact resistance loss, and wire speed changes, establishing independent compensation factors for each, and then using a fusion algorithm for synergistic action, which facilitates accurate fitting of the total heat demand. By uniformly scheduling power and frequency through the comprehensive compensation factor, synergistic adjustment of both is achieved, which helps to optimize energy transmission efficiency and equipment operating status while meeting heat demand. Traditional temperature control systems typically use PID control based on temperature deviation, which mixes component aging, environmental heat dissipation, contact loss, and speed fluctuations into a single error signal. This makes it impossible to distinguish the source of disturbance, resulting in poorly targeted compensation actions and a tendency to overcompensate or undercompensate. This application establishes four independent physical compensation factors, achieving decoupled identification and targeted compensation of disturbance sources. This helps solve the problem of maintaining a stable and uniform preheating temperature under varying operating conditions.

[0029] The copper-clad aluminum wire cladding preheating temperature composite control method provided in this application embodiment can be applied to a preheating temperature control device. In this case, the preheating temperature control device is the executing subject of the copper-clad aluminum wire cladding preheating temperature composite control method provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of preheating temperature control device.

[0030] For example, preheating temperature control equipment can be an industrial computer, programmable logic controller, embedded control system, distributed control system, tablet computer, laptop computer, ultra-mobile personal computer (UMPC), netbook, desktop computer, laptop computer, handheld computing device, etc., but is not limited to these.

[0031] To better understand the copper-clad aluminum wire preheating temperature composite control method provided in the embodiments of this application, the specific implementation process of the copper-clad aluminum wire preheating temperature composite control method provided in the embodiments of this application will be described by way of example below.

[0032] Figure 1 This illustration shows a schematic flowchart of a copper-clad aluminum wire preheating temperature composite control method provided in an embodiment of this application. The copper-clad aluminum wire preheating temperature composite control method includes: S100 acquires real-time operating data. This real-time operating data includes wire speed, current section temperature, ambient temperature, and contact resistance.

[0033] For example, a high-precision encoder or laser Doppler velocimeter can be used to measure the wire speed; an infrared thermometer or thermocouple can be installed at key points in the heating section to measure the workpiece surface temperature and obtain the current section temperature; a temperature sensor can be installed inside the equipment cabinet or outside the heating cavity to measure the ambient temperature; and a micro-ohmmeter or by measuring the ratio of the voltage drop across the electrodes to the current flowing through them can be used to dynamically calculate the contact resistance.

[0034] The S200 generates dynamic control parameters based on real-time operating data. These dynamic control parameters refer to the parameters that control the output power.

[0035] For example, dynamic control parameters can be PID parameters, PWM duty cycle, or other parameters used to control output power.

[0036] For example, the initial output power can be calculated based on real-time operating data, and then fine-tuned using PID (proportional-integral-derivative) feedback regulation to generate dynamic control parameters. For example, P base =k1 v (T target -T current )+k2 (T current -T amb ), where T target For the target temperature, T current The current temperature is given by k1, where k1 is the specific heat capacity coefficient and k2 is the heat dissipation coefficient. The output P of the PID feedback loop is... pid The dynamic output power is obtained by adjusting the initial output power. It cannot be changed abruptly, otherwise it will impact the power grid or cause mechanical vibration. A slope limiter can be set according to the dynamic output frequency to limit the rate of change of power, thus obtaining the dynamic control parameters.

[0037] S300, the first compensation factor is obtained based on the current segment temperature. This first compensation factor is used to reflect the control parameter compensation required due to aging or efficiency degradation of the heating element.

[0038] For example, the first compensation factor can be calculated based on the current segment temperature, for instance, the first compensation factor C1 = 1 + β (T target -T current ) η(trun), where β is the aging coefficient and η(trun) is an efficiency function with respect to running time (usually monotonically increasing, meaning the longer the time, the greater the compensation).

[0039] S400, a second compensation factor is obtained based on the ambient temperature. This second compensation factor is used to compensate for the control parameters required to reflect the heat loss caused by ambient heat dissipation conditions.

[0040] For example, the second compensation factor can be calculated based on the ambient temperature. For instance, the second compensation factor C2 = 1 + γ (T amb_ref -T amb ), where T amb_ref It is the standard ambient temperature (e.g., 25°C), T amb γ is the ambient temperature, and γ is the heat dissipation compensation coefficient.

[0041] S500, based on the contact resistance, derives a third compensation factor. This third compensation factor is used to compensate for the control parameters required to reflect the energy loss caused by the contact resistance.

[0042] For example, the third compensation factor can be calculated based on the contact resistance; for instance, the third compensation factor C3 = Or C3=1 / [1+δ (R c -R ref )], where R ref It is the standard contact resistance, R c δ is the actual contact resistance, and δ is the sensitivity coefficient.

[0043] S600, a fourth compensation factor is obtained based on the wire speed. This fourth compensation factor is used to compensate for the control parameters required to reflect changes in heating demand caused by variations in wire speed.

[0044] For example, the fourth compensation factor can be calculated based on the wire speed. For instance, the fourth compensation factor C4 = v ref / v, where v ref is the reference speed (which can be a preset rated speed or the speed of the previous stable production cycle), and v is the wire speed.

[0045] S700 integrates the first compensation factor, the second compensation factor, the third compensation factor, and the fourth compensation factor to obtain a comprehensive compensation factor.

[0046] For example, the comprehensive compensation factor can be calculated based on the first compensation factor C1, the second compensation factor C2, the third compensation factor C3, and the fourth compensation factor C4, such as... Figure 4 As shown. For example, the comprehensive compensation factor C total =C1 C2 C3 C4, to prevent overcompensation, can be set to C total The range, such as [0.5, 1.5].

[0047] S800 adjusts dynamic control parameters based on comprehensive compensation factors.

[0048] For example, it can be based on the comprehensive compensation factor C total Adjust the initial output power P output The final output power P is obtained final That is, P final =P output C total The dynamic control parameters are adjusted based on the final output power.

[0049] In one possible implementation, please refer to Figure 2 S300, based on the current segment temperature, obtains the first compensation factor, including: S310 determines the heating time required to reach the target temperature based on the current segment temperature.

[0050] For example, a multidimensional table (lookup table) can be created by pre-defining the time required to heat up to different target temperatures from different initial current temperatures. During actual operation, the system quickly obtains the heating time by interpolating and looking up the table based on the initial current temperature and the preset target temperature. Alternatively, historical data from normal equipment operation can be collected to establish a regression model (such as multiple linear regression, support vector regression, or neural network models) with the current temperature and target temperature as input and the heating time as output. The heating time required to reach the target temperature can then be determined based on the regression model.

[0051] S320 determines the rate of decrease in the current heating efficiency of the heating element relative to the initial heating efficiency based on the heating time.

[0052] For example, the rate of decrease in the current heating efficiency of the heating element relative to its initial heating efficiency can be calculated based on the heating time. For instance, the rate of decrease R... decay =(t real -t ref ) / t ref Or R decay =t real / t ref Among them, t ref The reference time, t, required to heat from the reference temperature to the target temperature real This is the heating time obtained from S310.

[0053] S330, the first compensation factor is calculated based on the attenuation ratio.

[0054] For example, the first compensation factor can be directly set to the attenuation ratio itself. To avoid unnecessary frequent compensation caused by small fluctuations due to measurement noise, a dead zone can be set. Compensation is only initiated when the attenuation ratio exceeds a certain threshold (e.g., 1.05, i.e., 5% attenuation), and the compensation amount is calculated starting from the threshold, for example, C1 = 1 + k. max(0,α−1−δ), where k is the compensation coefficient (usually k≥1) and δ is the dead zone.

[0055] Through steps S310 to S330, the aging trajectory of the heating element can be dynamically tracked. As the element efficiency declines, the first compensation factor gradually increases, adjusting the control parameters in real time. Even at the end of the heating element's lifespan, the equipment's core performance indicators, such as temperature control accuracy and heating response speed, can still maintain a level similar to that of brand-new equipment, which helps extend the duration of the effective process window. Precise compensation helps avoid over-compensation. In existing technologies, operators often set a high safety margin, leading to long-term energy waste. However, this invention, by accurately calculating the required compensation amount, precisely matches the energy input with actual needs, compensating for aging losses while avoiding unnecessary energy consumption.

[0056] Even after replacing heating elements from different batches with slightly different initial efficiencies, the system can quickly learn the characteristics of the new elements through adaptive steps S310 to S330 and automatically adjust the compensation factor, allowing the control parameters to quickly adapt to the new hardware without the need for manual readjustment of complex control parameters. This improves the robustness and generalization ability of the control system under different hardware conditions.

[0057] In one possible implementation, please refer to Figure 2 S400, based on the ambient temperature, derives a second compensation factor, including: S410 calculates the heat loss power based on the ambient temperature. The heat loss power refers to the heat power lost by the preheating equipment to the surrounding environment under current environmental conditions.

[0058] For example, the heat dissipation loss power can be calculated based on the ambient temperature. For instance, the heat dissipation loss power P... loss =h A (T device -T amb ), where h: overall heat dissipation coefficient (unit: W / (m²)). 2 K), h can be obtained through experimental calibration, or selected as an empirical value based on the surface material of the equipment and airflow conditions (such as whether forced air cooling is present). (For example, h is approximately 5–25 for natural convection and can reach 50–100 for forced convection). A: Effective heat dissipation surface area of ​​the equipment (unit: m²). 2 For tubular or strip-shaped heating elements, the outer surface area in contact with air is typically taken as the reference. device The current operating temperature of the equipment (or the set temperature of the heating section), in K or °C. amb The ambient temperature is collected in real time. In actual control systems, to simplify online calculations, h⋅A can be combined into a single constant K. lossOffline experiments were conducted to determine the steady-state power required to maintain the temperature under stable operating conditions, and K was then calculated. loss .

[0059] S420, the heat loss increment is obtained based on the heat loss power.

[0060] For example, the heat loss increment (ΔPloss) refers to the change in heat dissipation power caused by the current environment relative to a certain baseline environmental state. For example, ΔP loss =P loss_current -P loss_reference , where P loss_current The power loss due to heat dissipation is calculated based on the current ambient temperature. P loss_reference Based on the reference ambient temperature (e.g., T) amb_ref The heat loss power was calculated at 20℃.

[0061] S430, the second compensation factor is calculated based on the increase in heat loss.

[0062] For example, a second compensation factor can be calculated based on the increase in heat loss, for instance, if the current base output power is P. base (This can be the initial output power or the power output value at the previous moment), then the second compensation factor is: C2 = 1 + ΔP loss / P base ΔP can also be established. loss A linear mapping function to the compensation factor. A maximum compensation range is set, for example, when ΔP... loss The maximum possible value (e.g., at an extreme low temperature of -20℃) corresponds to C. max (As shown in 1.3), through linear interpolation, we obtain: C2 = 1 + ΔP loss / ΔP loss_max ×(C max -1).

[0063] Through steps S410 to S430, the ambient temperature is converted into heat dissipation loss power, giving the compensation amount a clear physical meaning. Each additional output of the control system can correspondingly offset the measured heat dissipation increment, avoiding temperature overshoot or energy waste caused by blindly increasing output. At the reference environmental point, the compensation factor is 1, and the system degenerates into pure feedback control, which is beneficial for improving stability under low complexity. When the environment deviates from the reference point, the compensation factor intervenes linearly, forming a cooperative mode of "feedforward dominance and feedback correction". This retains the robustness of feedback control while obtaining the speed of feedforward control.

[0064] In one possible implementation, please refer to Figure 2 S500, based on the contact resistance, derives a third compensation factor, including: S510 If the contact resistance is greater than the preset contact resistance threshold, the degree of contact loss is calculated based on the contact resistance.

[0065] For example, the degree of contact loss can be the ratio of power loss due to contact resistance to the effective heating power of the heating element, or it can be directly characterized as efficiency degradation relative to a reference state. When the contact resistance is greater than a preset contact resistance threshold, the degree of contact loss can be calculated based on the contact resistance. For example, the degree of contact loss δ... c =I 2 (R c -R c0 ) / P heater Where I: the current flowing through the heating element (unit: A), which can be collected in real time by a current sensor. R c R: The currently measured or estimated contact resistance (unit: Ω). c0 Initial (or healthy state) contact resistance reference value (unit: Ω). Typically calibrated after initial installation or maintenance of the equipment. P heater The current effective output power of the heating element (in W) can be either real-time power or rated power.

[0066] S520, calculate the third compensation factor based on the degree of contact loss.

[0067] For example, a third compensation factor can be calculated based on the degree of contact loss, such as the third compensation factor C3 = 1 + α. δ c , where δ c To determine the degree of contact loss, α is a compensation coefficient, which can take a value of 1 or slightly greater than 1 (e.g., 1.05), or C3 = 1 / (1−δ). c ).

[0068] Through steps S510 to S520, the power loss caused by contact resistance is separated from the total output power and compensated specifically in the form of a compensation factor. When the contact resistance further increases, the compensation factor is automatically adjusted upwards. By integrating the concept of equipment health management (PHM) into the real-time control algorithm, the control system can not only "respond" to current process requirements but also "sense" the degradation of its own hardware status and make adaptive adjustments.

[0069] In one possible implementation, please refer to Figure 2 S600, based on wire speed, derives a fourth compensation factor, including: S610 determines the heating requirement per unit time based on the wire speed.

[0070] For example, the heating demand Q per unit time can be determined based on the wire speed.req (Unit: W or J / s), for example, Q req = c p (T target -T inlet ),in, Mass flow rate per unit time (unit: kg / s). For wire, =ρ A cross v, where ρ is the wire density (kg / m²) 3 A cross The cross-sectional area of ​​the wire (m) 2 v is the wire speed (m / s). c p Specific heat capacity of wire (unit: J / (kg⋅K)), which is the amount of heat required to raise the temperature of one kilogram of material by 1 K. This value usually varies with temperature, but in simplified engineering calculations, the average specific heat capacity is often taken. T target Target process temperature (unit: °C or K). T inlet The initial temperature of the wire before it enters the heating zone (unit: °C or K) is usually close to the ambient temperature, but can also be collected in real time by a temperature sensor.

[0071] S620 calculates the heating power required to reach the target temperature based on heating needs.

[0072] For example, the heating power required to reach the target temperature can be calculated based on the heating demand, such as the heating power P required to reach the target temperature. required =η Q req , where Q req : Theoretical heat demand per unit time (W), η: Preset heat transfer efficiency coefficient η (0<η≤1).

[0073] S630 calculates the fourth compensation factor based on the ratio of heating power to reference power.

[0074] For example, under the baseline operating condition where the wire speed is equal to a preset standard speed and other conditions (wire specifications, inlet temperature, etc.) are all in standard state, the baseline power calculated by S610 and S620 can be denoted as P. ref Then the fourth compensation factor C4 = P required / P ref , where P required This represents the actual required heating power calculated by S620 under the current operating conditions.

[0075] Through steps S610 to S630, a precise mathematical model from speed to heat demand is established, which helps improve the temperature control accuracy of the system under variable speed conditions. The modular design ensures that various compensation factors are independent and do not interfere with each other, facilitating step-by-step debugging, fault isolation, and maintenance upgrades. The resulting comprehensive compensation factor fully covers all physical factors affecting the heating process, achieving globally optimal control under complex operating conditions.

[0076] In one possible implementation, please refer to Figure 3 The methods also include: S001, determine the rate of temperature change along the length direction based on the wire speed.

[0077] For example, this can be based on a given maximum permissible space temperature gradient (dT / dx). max (That is, to ensure that the internal thermal stress of the material does not exceed the allowable value, the temperature rise per meter must not exceed a certain value) and the wire speed determines the maximum possible rate of temperature change along the length: (dT / dt) max =v (dT / dx) max .

[0078] S002, determine the maximum allowable temperature deviation range based on the target temperature.

[0079] For example, the corresponding maximum temperature deviation range can be determined based on the target temperature mapping. For instance, when the target temperature is less than 300°C, the maximum temperature deviation range is the target temperature ±5°C.

[0080] S003, adjust the temperature gradient threshold according to the rate of temperature change and the maximum temperature deviation range.

[0081] For example, the temperature gradient threshold can be adjusted according to the rate of temperature change and the maximum temperature deviation range; for example, the temperature gradient threshold G. max =min((dT / dt) max ,ΔT tol / t ramp ), where ΔT tol The maximum temperature deviation that can be obtained through S002 is t. ramp The shortest allowable time for the heating process (determined by the production cycle).

[0082] Through steps S001 to S003, the heating rate limit can be adjusted in real time according to the wire speed. When the production line speeds up, the gradient threshold automatically increases to keep the heating rate up; when it slows down, the gradient threshold automatically decreases to prevent overshoot caused by excessively rapid heating. By using the spatial gradient as a constraint, the rate of temperature change along the length direction is limited, which helps prevent internal thermal stress cracking of the material. Especially during continuous heating, an excessively large spatial gradient can easily lead to uneven local thermal expansion of the wire, generating residual stress or even fracture.

[0083] In one possible implementation, please refer to Figure 3 S200 generates dynamic control parameters based on real-time operating condition data, including: S210 divides the temperature control zone in real time based on real-time operating data. The temperature control zone includes a heating zone, a transition zone, and a stabilization zone.

[0084] For example, multiple temperature sensors (such as infrared thermometers or thermocouple arrays) can be arranged along the heating path to collect the temperature at each point in real time. By calculating the first derivative of temperature with respect to distance, i.e., the spatial gradient, and setting a gradient threshold, the region boundaries can be dynamically identified, and the temperature control area can be divided.

[0085] S220 uses the central difference method to calculate the temperature gradient of the temperature control region.

[0086] For example, for sensors arranged at equal intervals (interval Δx), the center difference formula is: G(x) i )=[T(x i+1 )−T(x i−1 )] / 2Δx, where T(x i ) represents the position x i The temperature at point i, i=1,2,…,n−1. The boundary gradient of each region within the temperature-controlled region can be calculated using the central difference formula, and the average temperature gradient of the temperature-controlled region can be obtained, such as… Figure 5 As shown.

[0087] S230, the dynamic control parameters are calculated based on the temperature gradient.

[0088] For example, the dynamic control parameter may include: proportional gain K p Integration time T i Differential time T d (For PID controllers). Dynamic control parameters can be determined using linear interpolation or fuzzy rules based on the average temperature gradient G of the temperature control region and the boundary gradients of each region within the temperature control region. For example, K p =K p0 [1+α (G−G low ) / (G high -G low )], T i =T i0 / [1+α (G−G low ) / (G high -G low )], T d =T d0 [1+α (G−G low ) / (G high -G low )], where K p0 T i0 and T d0 The reference PID parameters are α, the adjustment coefficient, and G. high G represents the boundary gradient of the heating zone. low This represents the boundary gradient of the stable region.

[0089] Through steps S210 to S230, the gradient information is superimposed on the power output as a feedforward quantity, forming a temperature field-based feedforward compensation. When the gradient increases, it is predicted that there will be a large amount of heat demand, and the output is increased in advance; when the gradient decreases, it is predicted that the output will approach the set value, and the output is reduced in advance. This helps to reduce temperature overshoot, and is especially suitable for production scenarios with variable speed and specifications.

[0090] Optionally, please refer to Figure 3 S230, the dynamic control parameters are calculated based on the temperature gradient, including: S231, determine the temperature gradient difference between adjacent sub-regions in the temperature control area based on the temperature gradient.

[0091] For example, the temperature gradient difference between adjacent sub-regions in the temperature control region, i.e., ΔG, can be determined based on the temperature gradient. i =G(x i+1 )−G(x i ).

[0092] S232, when the temperature gradient difference is greater than the temperature gradient threshold, adjust the distribution ratio of heating power of adjacent sub-regions in the temperature control area according to the temperature gradient difference.

[0093] For example, when the temperature gradient difference is greater than a temperature gradient threshold, the distribution ratio of heating power between adjacent sub-regions in the temperature control region is adjusted according to the temperature gradient difference. For example, δP=K bal ⋅(ΔG i −ΔG th), where δP is the power increment (expressed as a percentage or absolute value of rated power) that needs to be transferred from the high gradient region to the low gradient region, and K bal ΔG is the preset balance coefficient. th This is the temperature gradient threshold.

[0094] S233 determines dynamic control parameters based on the allocation ratio.

[0095] For example, the ratio of the heating power of each sub-region to be adjusted relative to the reference power can be determined according to the distribution ratio of the heating power of adjacent sub-regions, and the ratio of the heating power of each sub-region to be adjusted relative to the reference power can be determined as the distribution coefficient, and the distribution coefficient can be determined as the dynamic control parameter, thereby adjusting the output power.

[0096] Through steps S231 to S233, gradient difference detection and power redistribution enable active control of the temperature distribution shape, rather than passively waiting for feedback errors. On-demand power allocation ensures a more balanced load on each heating element, extending equipment lifespan. Simultaneously, total power remains constant, preventing an increase in overall energy consumption.

[0097] 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.

[0098] Corresponding to the copper-clad aluminum wire preheating temperature composite control method described in the above embodiments, this application also provides a copper-clad aluminum wire preheating temperature composite control device. Each module of the device can realize each step of the copper-clad aluminum wire preheating temperature composite control method. Figure 6 The diagram shows a structural block diagram of the copper-clad aluminum wire preheating temperature composite control device provided in the embodiments of this application. For ease of explanation, only the parts related to the embodiments of this application are shown.

[0099] Reference Figure 6 The device includes: The acquisition module is used to acquire real-time operating condition data; wherein, the real-time operating condition data includes wire speed, current segment temperature, ambient temperature, and contact resistance; The dynamic control parameter module is used to generate dynamic control parameters based on the real-time operating data; wherein, the dynamic control parameters refer to parameters for controlling the output power; The first compensation factor module is used to obtain a first compensation factor based on the current segment temperature; wherein, the first compensation factor is used to reflect the control parameter compensation required for the heating element due to aging or efficiency decay. The second compensation factor module is used to obtain a second compensation factor based on the ambient temperature; wherein, the second compensation factor is used to reflect the control parameter compensation required to reflect the heat loss caused by the ambient heat dissipation conditions. The third compensation factor module is used to obtain a third compensation factor based on the contact resistance; wherein the third compensation factor is used to reflect the control parameter compensation required to reflect the energy loss caused by the contact resistance. The fourth compensation factor module is used to obtain a fourth compensation factor based on the wire speed; wherein, the fourth compensation factor is used to reflect the control parameter compensation required to reflect the change in heating demand caused by the change in wire speed; The comprehensive compensation factor module is used to fuse the first compensation factor, the second compensation factor, the third compensation factor and the fourth compensation factor to obtain a comprehensive compensation factor; The adjustment module is used to adjust the dynamic control parameters according to the comprehensive compensation factor.

[0100] It should be noted that the information interaction and execution process between the above modules are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.

[0101] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units and modules in the above device can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0102] This application also provides a preheating temperature control device. Figure 7 This is a schematic diagram of the preheating temperature control device provided in one embodiment of this application. Figure 7 As shown, the preheating temperature control device 7 of this embodiment includes: at least one processor 70 ( Figure 7 Only one is shown in the image), at least one memory 71 ( Figure 7(Only one is shown in the image) and a computer program 72 stored in the at least one memory 71 and executable on the at least one processor 70. When the processor 70 executes the computer program 72, it causes the preheating temperature control device 7 to perform the steps in any of the above embodiments of the copper-clad aluminum wire cladding preheating temperature composite control method, or causes the preheating temperature control device 7 to perform the functions of each module / unit in the above embodiments of the apparatus.

[0103] For example, the computer program 72 may be divided into one or more modules / units, which are stored in the memory 71 and executed by the processor 70 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 72 in the preheating temperature control device 7.

[0104] The preheating temperature control device 7 can be a computing device such as an industrial computer, programmable logic controller, desktop computer, laptop, handheld computer, or cloud server. This preheating temperature control device may include, but is not limited to, a processor 70 and a memory 71. Those skilled in the art will understand that... Figure 7 This is merely an example of the preheating temperature control device 7 and does not constitute a limitation on the preheating temperature control device 7. It may include more or fewer components than shown, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0105] The processor 70 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.

[0106] In some embodiments, the memory 71 may be an internal storage unit of the preheating temperature control device 7, such as a hard disk or memory of the preheating temperature control device 7. In other embodiments, the memory 71 may be an external storage device of the preheating temperature control device 7, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the preheating temperature control device 7. Further, the memory 71 may include both internal storage units and external storage devices of the preheating temperature control device 7. The memory 71 is used to store operating systems, applications, bootloaders, data, and other programs, such as the program code of computer programs. The memory 71 can also be used to temporarily store data that has been output or will be output.

[0107] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0108] This application provides a computer program product that, when run on a preheating temperature control device, enables the preheating temperature control device to perform the steps described in any of the above method embodiments.

[0109] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or device capable of carrying the computer program code to the preheating temperature control device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, such as a USB flash drive, a portable hard drive, a magnetic disk, or an optical disk.

[0110] 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.

[0111] 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.

[0112] In the embodiments provided in this application, it should be understood that the disclosed preheating temperature control device and method can be implemented in other ways. For example, the preheating temperature 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.

[0113] 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.

[0114] 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 method for combined control of preheating temperature for copper-clad aluminum wire coating, characterized in that, include: Acquire real-time operating condition data; wherein, the real-time operating condition data includes wire speed, current segment temperature, ambient temperature, and contact resistance; Dynamic control parameters are generated based on the real-time operating data; wherein, the dynamic control parameters refer to parameters that control the output power. A first compensation factor is obtained based on the current segment temperature; wherein, the first compensation factor is used to reflect the compensation of control parameters required for the heating element due to aging or efficiency degradation; A second compensation factor is obtained based on the ambient temperature; wherein, the second compensation factor is used to reflect the control parameter compensation required to reflect the heat loss caused by the ambient heat dissipation conditions; A third compensation factor is obtained based on the contact resistance; wherein, the third compensation factor is used to reflect the control parameter compensation required to reflect the energy loss caused by the contact resistance; A fourth compensation factor is obtained based on the wire speed; wherein, the fourth compensation factor is used to compensate for the control parameters required to reflect the changes in heating demand caused by changes in wire speed; The first compensation factor, the second compensation factor, the third compensation factor, and the fourth compensation factor are fused together to obtain a comprehensive compensation factor; The dynamic control parameters are adjusted based on the comprehensive compensation factor.

2. The method for combined control of preheating temperature for copper-clad aluminum wire as described in claim 1, characterized in that, The step of obtaining the first compensation factor based on the current segment temperature includes: Determine the heating time required to reach the target temperature based on the current segment temperature; The rate of decrease in the current heating efficiency of the heating element relative to its initial heating efficiency is determined based on the heating time. The first compensation factor is calculated based on the attenuation ratio.

3. The method for combined control of preheating temperature for copper-clad aluminum wire as described in claim 1, characterized in that, The process of obtaining the second compensation factor based on the ambient temperature includes: The heat loss power is obtained based on the ambient temperature; wherein, the heat loss power refers to the heat power lost by the preheating equipment to the surrounding environment under the current environmental conditions; The heat loss increment is obtained based on the heat loss power. The second compensation factor is calculated based on the heat loss increment.

4. The method for combined control of preheating temperature for copper-clad aluminum wire as described in claim 1, characterized in that, The process of obtaining the third compensation factor based on the contact resistance includes: If the contact resistance is greater than a preset contact resistance threshold, the degree of contact loss is calculated based on the contact resistance. The third compensation factor is calculated based on the degree of contact loss.

5. The method for combined control of preheating temperature for copper-clad aluminum wire as described in claim 1, characterized in that, The process of obtaining the fourth compensation factor based on the wire speed includes: The heating requirement per unit time is determined based on the wire speed; Calculate the heating power required to reach the target temperature based on the heating requirements; The fourth compensation factor is calculated based on the ratio of the heating power to the reference power.

6. The method for combined control of preheating temperature for copper-clad aluminum wire as described in claim 1, characterized in that, The method further includes: The rate of temperature change along the length direction is determined based on the wire speed. Determine the maximum allowable temperature deviation range based on the target temperature; The temperature gradient threshold is adjusted based on the rate of temperature change and the maximum temperature deviation range.

7. The method for combined control of preheating temperature for copper-clad aluminum wire as described in claim 6, characterized in that, The generation of dynamic control parameters based on the real-time operating data includes: The temperature control zone is divided in real time based on the real-time operating data; wherein the temperature control zone includes a heating zone, a transition zone, and a stabilization zone; The temperature gradient of the temperature control region is calculated using the central difference method. The dynamic control parameters are calculated based on the temperature gradient.

8. The method for combined control of preheating temperature for copper-clad aluminum wire as described in claim 7, characterized in that, The calculation of the dynamic control parameters based on the temperature gradient includes: The temperature gradient difference between adjacent sub-regions in the temperature control region is determined based on the temperature gradient. If the temperature gradient difference is greater than the temperature gradient threshold, the distribution ratio of heating power in adjacent sub-regions in the temperature control area is adjusted according to the temperature gradient difference. The dynamic control parameters are determined based on the allocation ratio.

9. A composite control device for preheating temperature of copper-clad aluminum wire, characterized in that, include: The acquisition module is used to acquire real-time operating condition data; wherein, the real-time operating condition data includes wire speed, current segment temperature, ambient temperature, and contact resistance; The dynamic control parameter module is used to generate dynamic control parameters based on the real-time operating data; wherein, the dynamic control parameters refer to parameters for controlling the output power; The first compensation factor module is used to obtain a first compensation factor based on the current segment temperature; wherein, the first compensation factor is used to reflect the control parameter compensation required for the heating element due to aging or efficiency decay. The second compensation factor module is used to obtain a second compensation factor based on the ambient temperature; wherein, the second compensation factor is used to reflect the control parameter compensation required to reflect the heat loss caused by the ambient heat dissipation conditions. The third compensation factor module is used to obtain a third compensation factor based on the contact resistance; wherein the third compensation factor is used to reflect the control parameter compensation required to reflect the energy loss caused by the contact resistance. The fourth compensation factor module is used to obtain a fourth compensation factor based on the wire speed; wherein, the fourth compensation factor is used to reflect the control parameter compensation required to reflect the change in heating demand caused by the change in wire speed; The comprehensive compensation factor module is used to fuse the first compensation factor, the second compensation factor, the third compensation factor and the fourth compensation factor to obtain a comprehensive compensation factor; The adjustment module is used to adjust the dynamic control parameters according to the comprehensive compensation factor.

10. A preheating temperature control device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method as described in any one of claims 1 to 8.

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