A cable straightening auxiliary device and method for cable processing

Abstract

This invention discloses an auxiliary straightening device and method for cable processing, belonging to the technical field of cable manufacturing and processing equipment. The device includes: S1, constructing a drive structure: setting up a base platform and a hollow guide spindle; a linkage adjustment ring with an Archimedean spiral guide groove is sleeved outside the spindle; and a closed-loop stepper motor is used to drive the rotation of the linkage adjustment ring, with an elastic floating straightening component embedded inside; S2, locking the physical zero point; S3, calculating the matching feed amount; S4, performing dynamic straightening: the drive motor rotates relative to the physical zero point position by the target number of pulse steps, forcing the floating piston to compress the variable stiffness damping spring to apply pressure; during the straightening process, viscous damping grease filled between the slider base and the floating piston is used to dissipate vibration energy. This invention establishes a calculation benchmark by real-time monitoring of the contact state, ensuring the consistency of straightening pressure for different batches of cables and solving the quality fluctuation problem caused by human operation in traditional methods.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing and processing equipment, specifically to an auxiliary straightening device and method for cable processing. Background Technology

[0002] Currently, the cable processing and manufacturing industry primarily uses physical straightening processes to treat finished or semi-finished cables. This eliminates internal stress and bending memory generated during coiling, storage, or cooling, ensuring the straightness meets the requirements for subsequent installation or transmission. In conventional production lines, straightening equipment typically consists of a base, a transmission mechanism, and multiple sets of straightening rollers. The rollers apply a reverse bending torque to the cable to achieve plastic shaping. In actual operation, to accommodate different cable specifications, mechanical screw adjustment or pneumatic push rod drive is usually used to change the position of the straightening rollers, causing them to press against the cable surface. Operators set the corresponding feed rate or pressure according to process standards, ultimately achieving the straightening process for the cable.

[0003] However, with the expansion of cable applications (such as precision instruments and high-voltage transmission) and the diversification of insulation materials, straightening systems based on traditional rigid contact and experience-based adjustment present some problems and weaknesses. For example, the setting of straightening pressure relies excessively on manual experience and lacks a quantitative feedback mechanism, resulting in poor processing consistency between different batches and even within the same batch of cables. Due to the inherent diameter tolerances or microscopic surface irregularities in the cables, the rigid contact rollers cannot adaptively adjust their contact state during high-speed operation, easily causing indentations or physical damage to the relatively fragile cable insulation layer. Furthermore, when facing dynamic load changes caused by surface irregularities, existing rigid transmission chains struggle to effectively absorb and dissipate the generated high-frequency vibration energy, leading to decreased equipment operational stability and even affecting the final straightening effect, necessitating improvement.

[0004] The information disclosed in the background section is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide an auxiliary straightening device and method for cable processing to solve the problems mentioned in the background art. Specifically, the technical solution of this invention includes:

[0006] An auxiliary straightening method for cable processing includes:

[0007] S1. Constructing the drive architecture: Set up a base platform and a hollow guide spindle, and fit a linkage adjustment ring with an Archimedes spiral guide groove on the outside of the spindle, as well as a closed-loop stepper motor for driving the rotation of the linkage adjustment ring, and embed an elastic floating straightening component inside; the component includes a slider base, a floating piston and variable stiffness damping springs at the bottom of both.

[0008] S2. Lock the physical zero point: Control the closed-loop stepper motor to drive the linkage adjustment ring to rotate so that the components retract towards the center. Calculate the electromechanical coupling stiffness coefficient based on the motor phase current. When the growth trend of this coefficient matches the initial compression stiffness characteristics of the variable stiffness damping spring, lock the current position as the physical zero point position.

[0009] S3. Calculate the matching feed amount: Combine the physical properties of the cable with the force-displacement characteristics of the variable stiffness damping spring, calculate the spring compression amount corresponding to the target straightening pressure, and convert it into the target pulse steps of the drive motor through the geometric relationship of the Archimedes spiral guide groove.

[0010] S4. Perform dynamic straightening: The drive motor rotates the target pulse step relative to the physical zero point position, forcing the floating piston to compress the variable stiffness damping spring to apply pressure; during the straightening process, the vibration energy is consumed by the viscous damping grease filled between the slider base and the floating piston.

[0011] Preferably, in step S2, the specific process of calculating the electromechanical coupling stiffness coefficient includes:

[0012] The collected motor phase current sequence is subjected to moving average filtering.

[0013] Calculate the ratio of the current increment to the motor step increment at the current time relative to the previous time. Multiply this ratio by the preset system conversion coefficient and use this ratio as the real-time electromechanical coupling stiffness coefficient.

[0014] The real-time electromechanical coupling stiffness coefficient is compared with the pre-acquired dynamic background no-load stiffness noise reference value. If the coefficient is continuously greater than the sum of the dynamic background no-load stiffness noise reference value and the preset stiffness judgment threshold within a set period, it is determined that contact has occurred.

[0015] Preferably, in step S3, the geometric conversion of the Archimedes spiral guide groove is specifically as follows:

[0016] Utilizing the linear relationship between the polar diameter and polar angle of the Archimedean spiral, the required spring compression is linearly converted into the target rotation angle of the linkage adjustment ring. The Archimedean spiral guide groove is designed as a countersunk groove structure, and its lead setting needs to be coordinated with the holding torque of the closed-loop stepper motor to ensure that the load reaction torque within the working stroke is less than the motor locking torque, so as to ensure position locking and provide transmission efficiency.

[0017] Preferably, in step S1, the variable stiffness damping spring is specifically configured as a variable pitch conical helical spring.

[0018] The large end diameter of the variable stiffness damping spring is larger than the small end diameter, so that the stiffness of the variable stiffness damping spring is small in the initial stage of compression. As the compression increases, the effective number of coils decreases and the stiffness increases nonlinearly, thereby achieving initial flexible contact protection and later high stiffness support in step S4.

[0019] Preferably, in step S4, the mechanism by which the viscous damping grease filled between the slider base and the floating piston dissipates vibration energy is as follows:

[0020] A throttling annular gap of 0.08 mm to 0.12 mm is reserved between the inner cavity of the slider base and the floating piston;

[0021] When the change in cable diameter causes the floating piston to move relative to the slider base, it forces the high-viscosity damping grease to undergo strong shear flow between the upper and lower chambers of the floating piston through the throttling annular gap, using internal fluid friction and wall shear resistance to consume high-frequency vibration energy.

[0022] Preferably, a rectangular guide through hole is provided axially on the side wall of the hollow guide spindle in step S1;

[0023] The slider base has a T-shaped structure and is embedded in the rectangular guide hole, and the top of the slider base is provided with a guide pin;

[0024] The guide pin is inserted into the Archimedes spiral guide groove of the linkage adjustment ring, converting the rotational motion of the linkage adjustment ring into the radial linear motion of the slider base.

[0025] Preferably, the method for obtaining the dynamic background unloaded stiffness noise reference value before step S2 is as follows:

[0026] The drive motor is driven to rotate the linkage adjustment ring at a constant speed under no-load.

[0027] Collect motor phase current data within a continuous stroke and calculate the ratio sequence of current change to step change between adjacent sampling points within the stroke. Select the maximum value or root mean square value in the ratio sequence as the dynamic background no-load stiffness noise reference value.

[0028] An auxiliary straightening device for cable processing includes:

[0029] Base platform;

[0030] A hollow guide spindle is horizontally fixed above the base platform, and its sidewall has a rectangular guide through hole.

[0031] The linkage adjustment ring is rotatably sleeved on the outer wall of the hollow guide main shaft. The inner wall has an Archimedean spiral guide groove, and the outer wall has spur gear teeth.

[0032] The elastic floating straightening assembly includes a slider base embedded in the rectangular guide hole, a floating piston located within the slider base, and a variable stiffness damping spring located between the two; the slider base is engaged with the Archimedes spiral guide groove via a guide pin;

[0033] The drive and detection unit includes a closed-loop stepper motor that meshes with the spur gear and a current transformer for monitoring the current.

[0034] The central processing unit, electrically connected to the driving and detection unit, is used to perform the zero-point contact feature identification and nonlinear stiffness matching calculation. The internal logic of the central processing unit is specifically configured as follows: it includes a stiffness calculation module, used to calculate the electrical coupling stiffness coefficient based on the sampled current; and a contact determination module, used to compare the real-time calculated stiffness coefficient with the dynamic background no-load stiffness noise reference value to identify the physical zero point.

[0035] Preferably, the end of the floating piston is equipped with a straightening roller via a U-shaped fork, and the surface of the straightening roller is covered with a high-hardness wear-resistant elastomer layer;

[0036] The inner wall of the slider base is provided with a sealing and retaining component, which together with the floating piston forms a closed chamber, and the closed chamber is filled with viscous damping grease.

[0037] Compared with the prior art, the present invention has the following improvements and advantages:

[0038] 1. This solution constructs a drive architecture that includes a base platform, a hollow guide spindle, and a linkage adjustment ring. It uses the changes in motor phase current to calculate the electromechanical coupling stiffness coefficient in real time, thereby automatically locking the physical zero point position. This method eliminates the reliance on human experience and establishes a calculation benchmark by monitoring the contact state in real time, ensuring the consistency of straightening pressure for different batches of cables and solving the quality fluctuation problem caused by human operation in traditional methods.

[0039] 2. This solution is equipped with a variable pitch conical helical spring. In the initial stage of compression, the large-diameter coil deforms first to provide low stiffness, which realizes flexible contact protection for the cable insulation layer. As the compression increases, the effective number of turns decreases and the stiffness increases nonlinearly, providing sufficient high stiffness support to overcome the internal stress of the cable. This variable stiffness characteristic solves the problem that a single stiffness spring cannot simultaneously satisfy the contradiction of not damaging the cable and effectively straightening.

[0040] 3. This solution utilizes viscous damping grease filled in the closed cavity between the slider base and the floating piston, combined with a 0.1mm throttling annular gap to construct a micro hydraulic damping system. When the unevenness of the cable surface causes high-frequency vibration of the floating piston, the damping grease generates strong fluid shear resistance through the narrow gap, converting kinetic energy into heat energy dissipation. This mechanism effectively absorbs vibration energy, suppresses piston bounce, and ensures the smooth and continuous straightening process, which is superior to the stability of traditional undamped structures.

[0041] 4. Before performing contact detection, this solution first obtains the dynamic background no-load friction reference value, that is, the average current value when the motor rotates at a constant speed under no-load. In subsequent judgment, contact is only determined when the real-time stiffness coefficient is continuously greater than the reference value. This logic eliminates misjudgment caused by uneven friction of the mechanical structure itself, significantly improves the signal-to-noise ratio of identifying real contact signals in noisy industrial environments, and ensures the accuracy of zero-point locking. Attached Figure Description

[0042] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0043] Figure 1 This is a schematic diagram of the overall structure of the device from the front.

[0044] Figure 2 This is a schematic diagram of the overall structure of the back of the device;

[0045] Figure 3 This is a schematic diagram of the structure of the elastic floating straightening component;

[0046] Figure 4 This is a schematic diagram of a floating piston and its connection structure;

[0047] Figure 5 This is a schematic diagram of the process flow of the method of the present invention.

[0048] In the diagram: 110, hollow guide spindle; 120, base platform; 130, rectangular guide through hole; 200, linkage adjustment ring; 210, Archimedes spiral guide groove; 220, spur gear teeth; 300, elastic floating straightening assembly; 310, slider base; 311, guide pin; 320, floating piston; 330, straightening roller; 340, variable stiffness damping spring; 400, drive and detection unit; 410, closed-loop stepper motor; 420, driving pinion; 430, current transformer; 500, central processing unit. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0050] Example 1:

[0051] Please see Figure 1-5 This invention provides an auxiliary straightening method for cable processing, comprising:

[0052] S1. Constructing the drive architecture: A base platform 120 and a hollow guide spindle 110 are set up. A linkage adjustment ring 200 with an Archimedes spiral guide groove 210 is sleeved on the outside of the spindle, and a closed-loop stepper motor 410 for driving the linkage adjustment ring 200 to rotate is also set up. An elastic floating straightening component 300 is embedded inside. The component includes a slider base 310, a floating piston 320, and variable stiffness damping springs 340 at the bottom of both. At the same time, the closed-loop stepper motor 410 is configured to mesh with the linkage adjustment ring 200 through a drive pinion 420.

[0053] S2. Lock the physical zero point: Control the closed-loop stepper motor to drive the linkage adjustment ring 200 to rotate so that the components are gathered towards the center. Calculate the electromechanical coupling stiffness coefficient based on the motor phase current. When the growth trend of this coefficient matches the initial compression stiffness characteristics of the variable stiffness damping spring 340, lock the current position as the physical zero point position.

[0054] S3. Calculate the matching feed amount: Combine the physical properties of the cable with the force-displacement characteristics of the variable stiffness damping spring 340, calculate the spring compression amount corresponding to the target straightening pressure, and convert it into the target pulse steps of the drive motor through the geometric relationship of the Archimedes spiral guide groove 210.

[0055] S4. Perform dynamic straightening: The drive motor rotates the target number of pulse steps relative to the physical zero point position, forcing the floating piston 320 to compress the variable stiffness damping spring 340 to apply pressure; during the straightening process, the vibration energy is consumed by the viscous damping grease filled between the slider base 310 and the floating piston 320.

[0056] In this embodiment, an auxiliary straightening method for cable processing mainly solves the problem of poor consistency caused by relying on manual experience to set the straightening pressure in the prior art, and also solves the problem that rigid contact can easily damage the cable insulation layer.

[0057] The drive architecture is constructed as the foundation, and the base platform 120 and the hollow guide spindle 110 provide rigid support to ensure that the cable is transmitted along the central axis; the Archimedes spiral guide groove 210 cooperates with the elastic floating straightening component 300 to convert the rotational motion into radial linear motion.

[0058] In the process of locking the physical zero point, considering the tolerance of cable diameters in different batches, the system does not preset a fixed position, but instead senses the contact status by monitoring the changes in motor phase current in real time; when the impedance characteristics reflected by the current data change in a specific way, it is determined that contact has occurred and a calculation benchmark is established.

[0059] In the step of calculating the matching feed rate, the central processing unit 500, based on the input physical properties of the cable and combined with the mechanical characteristics of the variable stiffness damping spring 340, uses a pre-set cable property-pressure database. According to the input cable diameter and insulation yield strength, it retrieves the minimum radial pressure value required to induce plastic deformation in the cable by looking up a table. Specifically, the system's preset pressure calculation model conforms to the formula:

[0060]

[0061] in, The yield strength of the insulating material. The outer diameter of the cable. These are dimensional empirical coefficients fitted based on historical experimental data, with dimensions [missing information]. To correct the consistency of units on both sides of the formula, for example, by taking values ​​of 0.8-1.2; or by directly calling a database containing preset parameters, such as setting the target straightening pressure to 500N for PVC insulated, 20mm diameter cables; using this as the target straightening pressure, and deriving the required compression displacement in reverse, and further converting it into the number of motor pulses to achieve quantitative control.

[0062] During the dynamic straightening process, the nonlinear characteristics of the variable stiffness damping spring 340 are utilized to provide flexible contact in the initial stage to avoid damaging the cable; and to provide sufficient stiffness in the later stage to overcome internal stress. At the same time, the flow of viscous damping grease in the tiny gaps generates shear resistance, absorbing the high-frequency vibration energy caused by cable unevenness and maintaining the stability of the straightening process.

[0063] In step S2, the specific process of calculating the electromechanical coupling stiffness coefficient includes:

[0064] The collected motor phase current sequence is subjected to moving average filtering.

[0065] Calculate the ratio of the current increment relative to the previous time step to the motor step increment, and multiply this ratio by a preset system conversion coefficient. The calculation formula is:

[0066]

[0067] in, The torque constant of the motor is expressed in units of 1000 ppm. , This is the gear reduction ratio. The lead of the Archimedean spiral groove, in units of . , The motor step angle, in units of , This is the mechanical transmission efficiency coefficient; the constant 1000 in the formula is used as a numerator to convert the meters in the torque constant to millimeters, consistent with the lead, to ensure that the unit of the finally calculated stiffness coefficient is... Furthermore, this calculation model is based on the linear characteristic region of the motor operating in a quasi-static low-speed feed mode, and ignores the influence of rotational inertia on the transient current.

[0068] This coefficient is used to compare the real-time electromechanical coupling stiffness coefficient with the pre-acquired dynamic background no-load stiffness noise reference value. If the coefficient is continuously greater than the sum of the dynamic background no-load stiffness noise reference value and the preset stiffness judgment threshold within a set period, it is determined that contact has occurred.

[0069] In this embodiment, the process of calculating the electromechanical coupling stiffness coefficient aims to extract real contact signals from a noisy industrial environment.

[0070] The central processing unit 500 collects the phase current data of the closed-loop stepper motor 410 through the current transformer 430. Ordinary open-loop stepper motors have a constant current and cannot reflect the load. The closed-loop stepper motor 410 controller specially selected in this embodiment contains a current loop. Its stator current increases monotonically with the increase of the rotor lag angle, thus providing a physical basis for serving as a load sensor. Since there is electromagnetic noise during motor operation, directly using the raw data will lead to misjudgment. Therefore, the collected motor phase current sequence is subjected to moving average filtering to smooth out high-frequency glitches and obtain a stable current trend.

[0071] The calculation of the real-time electromechanical coupling stiffness coefficient utilizes the discretized expression of stiffness in physics, namely the force change generated per unit displacement. Here, the current increment represents the torque increment, and the motor step increment represents the displacement increment. The ratio of the two eliminates the interference of speed variables and intuitively reflects the rate of change of load impedance.

[0072] The model is based on the quasi-static process assumption, which is that under extremely low-speed feed conditions, such as when the motor speed is controlled below 60 rpm, the influence of the inertial torque of the motor rotor and transmission components is ignored, and the back electromotive force and inductance effect of the motor are extremely small and negligible. It is assumed that the current change is mainly caused by the change in the stiffness of the external load.

[0073] By comparing the real-time electromechanical coupling stiffness coefficient with the dynamic background no-load friction reference value, a discrimination threshold is set. Only when the real-time calculated stiffness coefficient is continuously and stably greater than the sum of the dynamic background no-load stiffness noise reference value and the preset stiffness judgment threshold within the set sampling period, and the growth trend conforms to the initial compression characteristics of the spring, is it judged as physical contact. This logic eliminates instantaneous current fluctuations caused by uneven friction of the mechanical structure itself, ensuring the accuracy of zero-point locking.

[0074] Specifically, by calculating the real-time electromechanical coupling stiffness coefficient, when the coefficient value falls within the preset initial stiffness range of the spring, such as 0.5 N / mm to 1.5 N / mm, the characteristic match is confirmed;

[0075] In step S3, the geometric conversion of the Archimedes spiral guide groove 210 is specifically as follows:

[0076] Utilizing the linear relationship between the polar diameter and polar angle of the Archimedean spiral, the required spring compression is linearly converted into the target rotation angle of the linkage adjustment ring 200. The Archimedean spiral guide groove 210 is designed as a countersunk groove structure, and its lead setting needs to be coordinated with the holding torque of the closed-loop stepper motor to ensure that the load reaction torque within the working stroke is less than the motor locking torque, so as to ensure position locking and provide transmission efficiency.

[0077] In this embodiment, the geometric relationship conversion of the Archimedes spiral guide groove 210 establishes a deterministic mapping between linear displacement and angular displacement.

[0078] The central processing unit 500 derives the required spring compression amount using trigonometric relationships. Due to the linear characteristics of the Archimedes spiral guide groove 210, its radial lift is proportional to the rotation angle. The specific calculation logic uses the reciprocal of the tangent of the spiral lift angle to convert the radial linear compression amount into the circumferential rotation arc length, and then into the number of pulses of the closed-loop stepper motor 410.

[0079] Utilizing the property that the polar radius of the Archimedean spiral is linearly related to the polar angle, i.e. ,in For the target polar radius, For the guide, For radian angles, The initial extreme diameter of the Archimedean spiral guide groove, i.e., the base circle radius corresponding to the starting position of the guide groove, is used to linearly convert the required spring compression into the target rotation angle of the linkage adjustment ring; wherein, the Archimedean spiral guide groove is designed as a countersunk groove structure, and its lead... The settings must ensure that the maximum helix angle within the working stroke is less than the equivalent friction angle of the contact surface, for example, when setting the lead. for Millimeters, based on the effective extreme diameter range of the linkage adjustment ring within the working stroke, for example, 40mm to 60mm, so that the lift angle is maintained to Between these, to ensure self-locking and provide transmission efficiency.

[0080] The choice of this angle balances transmission efficiency and structural stability. Combined with the holding torque of the closed-loop stepper motor 410, it can effectively prevent the linkage adjustment ring 200 from reversing under load reaction force, providing a reliable position locking mechanism. When the motor stops driving, the component of the reaction force of the external cable decomposed into the tangential direction of the guide groove is less than the friction force, preventing the linkage adjustment ring 200 from reversing under load. This provides a passive safety mechanism while ensuring transmission efficiency.

[0081] In step S1, the specific structural configuration of the variable stiffness damping spring 340 is a variable pitch conical helical spring.

[0082] The large end diameter of the variable stiffness damping spring 340 is larger than the small end diameter, which makes the stiffness of the variable stiffness damping spring 340 relatively small in the initial stage of compression. As the compression increases, the effective number of coils decreases and the stiffness increases nonlinearly, thereby achieving initial flexible contact protection and later high stiffness support in step S4.

[0083] In this embodiment, the special configuration of the variable stiffness damping spring 340 solves the problem that a single stiffness spring cannot simultaneously address the contradiction between protection and straightening.

[0084] The variable stiffness damping spring 340 is selected as a variable pitch conical helical spring, with its geometric dimensions set as a large end diameter of 20mm and a small end diameter of 10mm. This conical structure makes the diameters of the spring coils inconsistent.

[0085] In the initial stage of compression, the large-diameter coil deforms first. At this time, the spring as a whole exhibits low stiffness characteristics, providing flexible contact for the cable insulation layer and avoiding indentation caused by excessive instantaneous impact force.

[0086] As the compression increases, the large-diameter coils gradually come into contact and cease to participate in deformation, reducing the effective number of working turns and causing a sharp, nonlinear increase in the overall stiffness of the spring. In the later stages of compression, the high stiffness provides sufficient radial pressure, forcing the cable to bend and deform to eliminate internal stress, thus achieving effective straightening.

[0087] In step S4, the mechanism by which the viscous damping grease filled between the slider base 310 and the floating piston 320 dissipates vibration energy is as follows:

[0088] A throttling annular gap of 0.08 mm to 0.12 mm is reserved between the inner cavity of the slider base 310 and the floating piston 320;

[0089] When the change in cable diameter causes the floating piston 320 to move relative to the slider base 310, it forces the high-viscosity damping grease to undergo strong shear flow between the upper and lower chambers of the floating piston 320 through the throttling annular gap, using internal fluid friction and wall shear resistance to consume high-frequency vibration energy.

[0090] In this embodiment, the mechanism of consuming vibration energy using viscous damping grease is achieved by constructing a miniature hydraulic damping system.

[0091] The inner cavity of the slider base 310 and the floating piston 320 are not completely fitted together, but rather a throttling annular gap of 0.08 mm to 0.12 mm is precisely machined in place; this closed cavity is filled with high-viscosity viscous damping grease. To achieve optimal shear damping effect in conjunction with the tiny gap of 0.08 mm to 0.12 mm, the viscous damping grease is preferably a high-molecular-weight silicone oil-based damping grease with a kinematic viscosity range of 5000 to 10000 cSt at 25°C; if the viscosity is too low, it will not provide sufficient damping, and if the viscosity is too high, it will cause sluggish piston response.

[0092] During the straightening process, when there are bamboo-like protrusions on the cable surface or the diameter locally increases, the floating piston 320 is subjected to force and generates radial displacement; this displacement forces the viscous damping grease to transfer between the upper and lower chambers separated by the piston through the narrow throttling annular gap.

[0093] Due to the extremely small throttling annular gap and extremely high fluid velocity, strong shearing forces are generated between fluid molecules and between the fluid and the wall. This process converts the high-frequency kinetic energy generated by the uneven cable of the floating piston 320 into heat energy and dissipates it. Due to the internal friction characteristics of the high-viscosity fluid, the shearing process is accompanied by significant viscous heating, thereby generating damping force to suppress the violent bouncing of the piston, prevent straightening failure, and ensure the smooth and continuous straightening process.

[0094] In step S1, a rectangular guide through hole 130 is provided on the side wall of the hollow guide spindle 110 along the axial direction;

[0095] The slider base 310 has a T-shaped structure and is embedded in the rectangular guide through hole 130, and the top of the slider base 310 is provided with a guide pin 311;

[0096] The guide pin 311 is inserted into the Archimedes spiral guide groove 210 of the linkage adjustment ring 200, converting the rotational motion of the linkage adjustment ring 200 into the radial linear motion of the slider base 310.

[0097] In this embodiment, the design of the hollow guide spindle 110 and the slider base 310 realizes the conversion and constraint of motion form.

[0098] The rectangular guide hole 130 on the side wall of the hollow guide spindle 110 provides the only moving channel for the slider base 310. The slider base 310 is designed with a T-shaped structure, which forms a sliding fit with the inner wall of the rectangular guide hole 130, strictly restricting the circumferential and axial degrees of freedom of the slider base 310, so that it can only move radially.

[0099] The guide pin 311 serves as the transmission medium, with one end fixed to the top of the slider base 310 and the other end inserted into the Archimedes spiral guide groove 210 on the inner wall of the linkage adjustment ring 200. When the motor drives the linkage adjustment ring 200 to rotate, the side wall of the spiral guide groove applies a tangential thrust to the guide pin 311. Since the slider base 310 is restricted from rotating, this thrust is forced to be converted into a radial component force, driving the slider base 310 to move towards the center or outward along the rectangular guide through hole 130, thereby realizing the synchronous opening and closing of multiple sets of straightening wheels.

[0100] The method for obtaining the dynamic background no-load stiffness noise reference value before step S2 is as follows:

[0101] The drive motor drives the linkage adjustment ring 200 to rotate at a constant speed under no-load.

[0102] Collect motor phase current data within a continuous stroke and calculate the ratio sequence of current change to step change between adjacent sampling points within the stroke. Select the maximum value or root mean square value in the ratio sequence as the dynamic background no-load stiffness noise reference value.

[0103] In this embodiment, the method for obtaining the dynamic background no-load friction reference value aims to eliminate the influence of the inherent resistance fluctuation of the system on the detection accuracy.

[0104] Before the cable is officially made in contact, the central processing unit 500 controls the closed-loop stepper motor 410 to drive the linkage adjustment ring 200 to rotate at a constant speed under no-load for a period of time. During this process, the torque output by the motor is mainly used to overcome bearing friction, guide groove friction and component inertia. These resistances constitute the basic background noise of the system.

[0105] The system collects motor phase current data during this continuous stroke via current transformer 430. The central processing unit 500 performs differential processing and statistical analysis on the data, eliminating instantaneous fluctuations, calculating the equivalent stiffness fluctuation sequence during no-load operation, and extracting the envelope peak value of this sequence. This peak value is set as the dynamic background no-load stiffness noise benchmark, representing the lower limit of the system's inherent stiffness noise caused by uneven mechanical friction under the current operating condition. When subsequently calculating contact stiffness, this benchmark value is used as the judgment baseline to ensure that the detected current increment originates entirely from the cable's reaction force, rather than fluctuations due to mechanical friction, thereby improving the signal-to-noise ratio for weak contact signal identification.

[0106] Example 2:

[0107] Please see Figure 1-4 An auxiliary straightening device for cable processing, comprising:

[0108] Base platform 120;

[0109] A hollow guide spindle 110 is horizontally fixed above the base platform 120, and a rectangular guide through hole 130 is provided on its side wall.

[0110] The linkage adjustment ring 200 is rotatably sleeved on the outer wall of the hollow guide main shaft 110. The inner wall has an Archimedean spiral guide groove 210, and the outer wall has spur gear teeth 220.

[0111] The elastic floating straightening assembly 300 includes a slider base 310 embedded in a rectangular guide through hole 130, a floating piston 320 located in the slider base 310, and a variable stiffness damping spring 340 located between the two; the slider base 310 is engaged with the Archimedes spiral guide groove 210 through a guide pin 311.

[0112] The drive and detection unit 400 includes a closed-loop stepper motor 410 that meshes with the spur gear teeth 220 and a current transformer 430 that monitors the current.

[0113] The central processing unit 500 is electrically connected to the drive and detection unit 400 and is used to perform zero-point contact feature recognition and nonlinear stiffness matching calculation. The internal logic of the central processing unit 500 is specifically configured as follows: it includes a stiffness calculation module, which is used to calculate the electrical coupling stiffness coefficient based on the sampled current; and a contact determination module, which is used to compare the real-time calculated stiffness coefficient with the dynamic background no-load stiffness noise reference value to identify the physical zero point.

[0114] In this embodiment, an auxiliary straightening device for cable processing achieves digital and adaptive control of the cable straightening process through the organic combination of various mechanical components.

[0115] The base platform 120 serves as the basic support, and the hollow guide spindle 110 is made of No. 45 steel and has been quenched. It is fixed by an L-shaped cast iron support seat to provide a high-strength mechanical skeleton for the device. The rectangular guide through holes 130 are distributed at 120° around the circumference to ensure uniform force in three directions.

[0116] The linkage adjustment ring 200 serves as a power distribution hub, mounted on the main shaft via a thrust ball bearing, retaining only rotational freedom. The spur gear teeth 220 on its outer wall receive power, while the Archimedes spiral guide groove 210 on its inner wall distributes displacement, thus realizing the synchronous drive of multiple components by a single power source.

[0117] The elastic floating straightening assembly 300 integrates actuation and buffering functions. The slider base 310 supports the entire assembly, the floating piston 320 directly transmits pressure, and the variable stiffness damping spring 340 provides non-linear restoring force. The three components work together to achieve a clamping effect that combines rigidity and flexibility.

[0118] In the drive and detection unit 400, the closed-loop stepper motor 410 serves as the power source, outputting precise rotation angles through the active pinion 420. The current transformer 430, connected in series in the drive circuit, acts as a sensor, converting changes in mechanical load into electrical signals.

[0119] The central processing unit 500 specifically adopts an industrial-grade PLC. Its built-in high-speed pulse output function controls the closed-loop stepper motor, and its analog signal acquisition function reads current data. Through internal algorithms, it performs zero-point identification and pressure calculation, replacing traditional manual operation and independent pressure sensors.

[0120] The end of the floating piston 320 is equipped with a straightening roller 330 via a U-shaped fork, and the surface of the straightening roller 330 is covered with a high-hardness wear-resistant elastomer layer.

[0121] The inner wall of the slider base 310 is provided with a sealing and retaining component, which together with the floating piston 320 forms a closed chamber, and the closed chamber is filled with viscous damping grease.

[0122] In this embodiment, the detailed design of the floating piston 320 and the straightening roller 330 is directly related to the product quality and the lifespan of the device.

[0123] As the component that directly contacts the cable, the straightening roller 330 has a surface coated with a high-hardness, wear-resistant elastomer layer. The choice of this material's hardness balances wear resistance and flexibility, allowing it to maintain its shape under high pressure to transmit straightening force, while also undergoing slight elastic deformation when the cable passes through joints or foreign objects, protecting the cable surface from scratches. Miniature deep groove ball bearings are embedded inside the roller, reducing frictional resistance during cable movement.

[0124] The sealing and retaining assembly uses an oil-resistant and wear-resistant Y-type rubber sealing ring, which is embedded in the sealing groove on the inner wall of the slider base 310. The lip of this sealing ring is in close contact with the outer cylindrical surface of the floating piston 320, forming a closed chamber together with the bottom of the slider base 310. The main function of this chamber is to seal the viscous damping grease, preventing it from leaking during the reciprocating motion of the piston, ensuring the long-term effectiveness of the damping energy absorption function, and also preventing external dust from entering the chamber and affecting the piston's motion accuracy.

[0125] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. An auxiliary straightening method for cable processing, characterized in that, include: S1. Constructing the drive architecture: A base platform (120) and a hollow guide spindle (110) are set up. A linkage adjustment ring (200) with an Archimedes spiral guide groove (210) is sleeved on the outside of the spindle, and a closed-loop stepper motor (410) for driving the linkage adjustment ring (200) to rotate is installed. An elastic floating straightening component (300) is embedded inside. The elastic floating straightening component (300) includes a slider base (310), a floating piston (320), and variable stiffness damping springs (340) at the bottom of both. S2, Locking the physical zero point: Control the closed-loop stepper motor (410) to drive the linkage adjustment ring (200) to rotate so that the components are gathered towards the center. Calculate the electromechanical coupling stiffness coefficient according to the motor phase current. When the growth trend of this coefficient matches the initial compression stiffness characteristics of the variable stiffness damping spring (340), lock the current position as the physical zero point position. S3. Calculate the matching feed amount: Combine the physical properties of the cable with the force-displacement characteristics of the variable stiffness damping spring (340), calculate the spring compression amount corresponding to the target straightening pressure, and convert it into the target pulse step of the drive motor through the geometric relationship of the Archimedes spiral guide groove (210); S4. Perform dynamic straightening: The drive motor rotates the target pulse step relative to the physical zero point position, forcing the floating piston (320) to compress the variable stiffness damping spring (340) to apply pressure; during the straightening process, the vibration energy is consumed by the viscous damping grease filled between the slider base (310) and the floating piston (320); In step S2, the specific process of calculating the electromechanical coupling stiffness coefficient includes: The collected motor phase current sequence is subjected to moving average filtering. Calculate the ratio of the current increment to the motor step increment at the current time relative to the previous time. Multiply this ratio by the preset system conversion coefficient and use this ratio as the real-time electromechanical coupling stiffness coefficient. The real-time electromechanical coupling stiffness coefficient is compared with the pre-acquired dynamic background no-load stiffness noise reference value. If the coefficient is continuously greater than the sum of the dynamic background no-load stiffness noise reference value and the preset stiffness judgment threshold within a set period, it is determined that contact has occurred. In step S3, the geometric conversion of the Archimedes spiral guide groove (210) is specifically as follows: Utilizing the linear relationship between the polar diameter and polar angle of the Archimedean spiral, the required spring compression is linearly converted into the target rotation angle of the linkage adjustment ring (200); wherein, the Archimedean spiral guide groove (210) is designed as a countersunk groove structure, and its lead setting needs to be coordinated with the holding torque of the closed-loop stepper motor to ensure that the load reaction torque within the working stroke is less than the motor locking torque, so as to ensure position locking and provide transmission efficiency; In step S4, the mechanism by which viscous damping grease is used to dissipate vibrational energy is as follows: A throttling annular gap of 0.08 mm to 0.12 mm is reserved between the inner cavity of the slider base (310) and the floating piston (320); When the change in cable diameter causes the floating piston (320) to move relative to the slider base (310), it forces the high-viscosity damping grease to undergo strong shear flow between the upper and lower chambers of the floating piston (320) through the throttling annular gap, and consumes high-frequency vibration energy by utilizing the internal friction of the fluid and the shear resistance of the wall. A rectangular guide hole (130) is provided axially on the side wall of the hollow guide spindle (110) in step S1. The slider base (310) is T-shaped and embedded in the rectangular guide hole (130), and the top of the slider base (310) is provided with a guide pin (311). The guide pin (311) is inserted into the Archimedes spiral guide groove (210) of the linkage adjustment ring (200) to convert the rotational motion of the linkage adjustment ring (200) into the radial linear motion of the slider base (310).

2. The auxiliary straightening method for cable processing as described in claim 1, characterized in that, In step S1, the specific structural configuration of the variable stiffness damping spring (340) is a variable pitch conical helical spring; The large end diameter of the variable stiffness damping spring (340) is larger than the small end diameter, so that the variable stiffness damping spring (340) has a small stiffness in the initial stage of compression. As the compression increases, the effective number of coils decreases and the stiffness increases nonlinearly, thereby achieving initial flexible contact protection and later high stiffness support in step S4.

3. The auxiliary straightening method for cable processing as described in claim 1, characterized in that, The method for obtaining the dynamic background unloaded stiffness noise reference value before step S2 is as follows: The drive motor drives the linkage adjustment ring (200) to rotate at a constant speed under no-load. Collect motor phase current data within a continuous stroke and calculate the ratio sequence of current change to step change between adjacent sampling points within the stroke. Select the maximum value or root mean square value in the ratio sequence as the dynamic background no-load stiffness noise reference value.

4. An auxiliary straightening device for cable processing, configured to perform an auxiliary straightening method for cable processing as described in any one of claims 1 to 3, characterized in that, include: Base platform (120); A hollow guide spindle (110) is horizontally fixed above the base platform (120), and a rectangular guide through hole (130) is provided on its side wall. The linkage adjustment ring (200) is rotatably sleeved on the outer wall of the hollow guide main shaft (110), with an Archimedes spiral guide groove (210) on the inner wall and a spur gear tooth (220) on the outer wall. The elastic floating straightening assembly (300) includes a slider base (310) embedded in the rectangular guide hole (130), a floating piston (320) located in the slider base (310), and a variable stiffness damping spring (340) located between the two; the slider base (310) is engaged with the Archimedes spiral guide groove (210) through a guide pin (311); The drive and detection unit (400) includes a closed-loop stepper motor (410) meshing with the spur gear teeth (220) and a current transformer (430) for monitoring the current. The central processing unit (500) is electrically connected to the driving and detection unit (400) and is used to perform the zero-point contact feature identification and nonlinear stiffness matching calculation. The internal logic of the central processing unit (500) is specifically configured as follows: it includes a stiffness calculation module for calculating the electrical coupling stiffness coefficient based on the sampled current; and a contact determination module for comparing the real-time calculated stiffness coefficient with the dynamic background no-load stiffness noise reference value to identify the physical zero point.

5. The auxiliary straightening device for cable processing as described in claim 4, characterized in that, The floating piston (320) has a straightening roller (330) mounted on its end via a U-shaped fork, and the surface of the straightening roller (330) is covered with a high-hardness wear-resistant elastomer layer. The inner wall of the slider base (310) is provided with a sealing and retaining component, which together with the floating piston (320) forms a closed chamber, and the closed chamber is filled with viscous damping grease.

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