A method and system for breakage prevention during copper clad steel wire drawing

Abstract

The application relates to the technical field of wire fracture prevention, in particular to a fracture prevention method and system for copper-coated steel wire stretching, which comprises the following steps: constructing a continuous state parameter sequence, extracting a stress transfer amount, a resistance release amount and a recovery delay amount based on the continuous state parameter sequence, and reconstructing a stress mapping sequence based on the stress transfer amount, the resistance release amount and the recovery delay amount; establishing a normal stretching fluctuation boundary and an abnormal accumulation boundary, obtaining a deviation value at a continuous sampling moment, comparing and analyzing the deviation value with the normal stretching fluctuation boundary and the abnormal accumulation boundary, and forming a fracture risk judgment result; and performing hierarchical control on the stretching speed in combination with the fracture risk judgment result. The application can reduce the risk accumulation state in advance before a high fracture risk is formed, so that the fracture probability is reduced, and the stability and continuity of the stretching production process are improved.

Description

Technical Field

[0001] This application relates to the field of wire breakage prevention technology, specifically a method and system for preventing breakage during tensile testing of copper-clad steel wire. Background Technology

[0002] In the continuous stretching production process of copper-clad steel wire, it needs to pass through the unwinding, multiple stretching stations, traction station, and take-up station in sequence. The diameter reduction is completed through tension transfer and speed coordination between each station. Since copper-clad steel wire is a composite material, its stress state during the stretching process is not only related to the operation of a single station, but also closely related to the load transfer between adjacent stations, changes in local resistance, and the recovery state after abnormal disturbances. Therefore, the risk of fracture usually has the characteristic of gradually accumulating and amplifying along the stretching path.

[0003] Existing anti-fracture measures mostly rely on tension over-limit alarms, wire breakage detection devices, or manual experience adjustments. They typically only stop or intervene when a fracture has already occurred or is about to occur, which is a passive protection method. It is difficult to identify the gradual abnormal process before fracture in a timely manner. At the same time, existing technologies are mostly based on a single parameter of tension, current, or speed, which is difficult to accurately reflect the real force transmission relationship between multiple workstations and to distinguish between normal fluctuations and abnormal accumulation. Especially when there are changes in material batches or equipment types, fixed threshold control strategies are not adaptable enough and are prone to false alarms or missed alarms. Therefore, it is difficult to achieve early identification and proactive reduction of the risk of tensile fracture of copper-clad steel wire. Summary of the Invention

[0004] To address the aforementioned issues, this application provides a method and system for preventing fracture during the stretching of copper-clad steel wire. By establishing a risk evolution benchmark based on material batches and equipment types, and by classifying and controlling the stretching speed according to the risk assessment results, the method can reduce the risk accumulation state before a high fracture risk is formed, thereby reducing the probability of fracture and improving the stability and continuity of the stretching production process.

[0005] This application adopts the following technical solution: a method for preventing fracture during tensile testing of copper-clad steel wire, comprising:

[0006] Along the stretching path of copper-clad steel wire, stretching characteristic parameters are collected synchronously at each workstation, and a continuous state parameter sequence is constructed by combining the positional relationship of each workstation on the stretching path.

[0007] Based on the continuous state parameter sequence, the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount are extracted, and the force mapping sequence is reconstructed based on the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount.

[0008] A risk evolution benchmark is established by combining material batches and equipment types. Based on the risk evolution benchmark, the normal tensile fluctuation boundary and the abnormal accumulation boundary are established. Based on the force mapping sequence and the comparison and analysis of the normal tensile fluctuation boundary and the abnormal accumulation boundary, a fracture risk judgment result is formed.

[0009] Based on the fracture risk assessment results, the tensile speed is controlled in stages to reduce the identified risk state in advance before it enters the high fracture risk state.

[0010] As a further description of the above technical solution: the method for constructing a continuous sequence of state parameters includes:

[0011] In the operating direction of the copper-clad steel wire drawing production line, the wire feeding station, each drawing station, traction station and take-up station are numbered sequentially.

[0012] Status acquisition units are deployed at each corresponding workstation to collect tensile characteristic parameters;

[0013] Based on the path distance between adjacent workstations and the corresponding running speed at the time, determine the transfer time of the wire from the previous workstation to the next workstation.

[0014] The status acquisition results of the front and rear workstations at the corresponding transfer time are matched so that the tensile characteristic parameters acquired by different workstations correspond to the continuous tensile process of the same wire.

[0015] The tensile characteristic parameters of the same wire at each workstation are combined into a set of continuous state parameters, which are then arranged in order of sampling to construct a continuous state parameter sequence.

[0016] As a further description of the above technical solution: the method for extracting the force transfer amount includes:

[0017] The continuous transfer process of the same wire segment between adjacent workstations is expanded, and an inter-workstation transfer analysis window is constructed. Based on the change sequence of tensile characteristic parameters at continuous sampling times of the previous and subsequent workstations, the output-side load change of the previous workstation and the receiving-side load change of the subsequent workstation are identified.

[0018] When it is determined that the load changes of the preceding and following workstations have a temporal correspondence and their response lag is within the allowable transmission time range, the continuous sampling intervals corresponding to the preceding and following workstations are determined as the effective response intervals.

[0019] The force transfer amount is determined based on the duration of the effective response interval and the degree of exceeding the threshold of the difference between each tensile characteristic parameter.

[0020] As a further description of the above technical solution: the method for determining the amount of force transfer includes:

[0021] The number of sampling points within the effective response interval is counted, and the duration of the effective response interval is obtained by multiplying the number of sampling points by the sampling period.

[0022] Within the effective response range, the operating speed difference and wire diameter difference of the previous station and the tension difference and current difference of the next station are extracted, and the above tensile characteristic parameter differences are compared with the corresponding thresholds to obtain the excess range of each tensile characteristic parameter difference relative to the corresponding threshold.

[0023] The excess values ​​are accumulated to obtain a comprehensive over-threshold value. The duration and comprehensive over-threshold value are normalized and then weighted and fused to obtain the force transfer value.

[0024] As a further description of the above technical solution: the method for obtaining the amount of delayed discharge is as follows:

[0025] Using the force transfer amount of the current workstation in the corresponding analysis period as the input transmission benchmark, the fluctuation amplitude of the tensile characteristic parameter corresponding to the workstation is extracted, and the fluctuation amplitude of the tensile characteristic parameter is normalized and then weighted and fused to obtain the actual fluctuation intensity.

[0026] Based on the force transfer amount of the current workstation in the corresponding analysis period, retrieve historical stable samples that match the force transfer amount under normal tensile conditions, and use the same calculation method as the actual fluctuation intensity to obtain the benchmark fluctuation intensity.

[0027] The actual fluctuation intensity is compared with the reference fluctuation intensity. When the actual fluctuation intensity is greater than the reference fluctuation intensity, the difference between the two is determined as the stabilizing amplification amount. When the actual fluctuation intensity is less than or equal to the reference fluctuation intensity, the stabilizing amplification amount is recorded as zero.

[0028] As a further description of the above technical solution: the method for obtaining the recovery hysteresis includes:

[0029] Based on the changes in tension fluctuation amplitude, current fluctuation amplitude, vibration enhancement amplitude, running speed reduction amplitude, and stagnation discharge amplitude at the current workstation during continuous sampling, the time for the abnormal disturbance to be resolved is determined.

[0030] Based on the changes in the state parameters of the corresponding workstation and subsequent workstations after the time when the abnormal disturbance is removed, the time when the stability is restored is determined, and the stability interval is obtained.

[0031] The recovery duration is determined based on the time length between the time when the abnormal disturbance is resolved and the time when stability is restored, and the recovery residual deviation is determined based on the difference between the state parameters after recovery and the stable state parameters before the disturbance.

[0032] The recovery hysteresis is determined based on the recovery duration and the recovery residual deviation.

[0033] As a further description of the above technical solution: the method for determining the recovery hysteresis based on the recovery duration and the recovery residual deviation includes:

[0034] The current recovery time is compared with the reference recovery time corresponding to the historical stable sample under normal stretching conditions to obtain the recovery time evaluation value.

[0035] The residual deviations corresponding to the tensile characteristic parameters within the recovery stable range are compared with their respective reference deviation values ​​to obtain the individual residual deviation evaluation quantity for each tensile characteristic parameter.

[0036] The residual deviation evaluation values ​​of each individual item are weighted and fused to obtain the recovery residual deviation evaluation value;

[0037] The recovery duration evaluation value and the recovery residual deviation evaluation value are weighted and fused according to a preset weight to obtain the recovery hysteresis.

[0038] As a further description of the above technical solution: the method for reconstructing the force mapping sequence based on the force transfer amount, the retardation amplification amount, and the recovery hysteresis amount includes:

[0039] Based on the correspondence of the same wire segment at each workstation and sampling time, the force transfer, retardation amplification, and recovery hysteresis corresponding to each workstation at each sampling time are bound to the workstation number, path location parameters, and time identifier to form a force mapping unit:

[0040] All force mapping units are arranged according to workstation order and time order to form a force mapping sequence.

[0041] As a further description of the above technical solution: the methods for establishing the boundaries of normal stretching fluctuations and abnormal accumulation include:

[0042] Obtain the material batch identifier and equipment type identifier corresponding to the current stretching task to construct a benchmark matching label. Based on the benchmark matching label, select force mapping sequence samples that are consistent with the current stretching task from historical normal production data to form a risk evolution benchmark sample set.

[0043] Based on the risk evolution benchmark sample set, the force transfer amount, the amount of stagnation and the amount of recovery hysteresis are statistically analyzed according to the work station number and the sampling time. The benchmark center value and normal fluctuation range corresponding to each work station and each sampling time are obtained respectively. The benchmark center values ​​are arranged in time order and work station order to form a risk evolution benchmark sequence.

[0044] The normal stretching fluctuation boundary is established based on the aforementioned risk evolution benchmark;

[0045] Establish anomaly accumulation boundaries based on historical anomaly samples.

[0046] As a further description of the above technical solution: the fracture risk determination results include normal tensile state, fluctuation warning state, risk accumulation state and high fracture risk state.

[0047] As a further description of the above technical solution: the methods for forming the fracture risk assessment result include:

[0048] The real-time acquired force mapping sequence is compared with the corresponding risk evolution benchmark at each work station and time step. The deviation direction and deviation magnitude of the current force transfer amount, the amount of stagnation and the amount of recovery hysteresis relative to the corresponding benchmark center value are calculated respectively, and the deviation value at continuous sampling time is obtained.

[0049] When the deviation value is within the normal stretching fluctuation boundary, it is judged as a normal deviation;

[0050] When the deviation value exceeds the normal stretching fluctuation boundary but does not enter the abnormal accumulation boundary, it is judged as a warning deviation;

[0051] When the deviation value enters the abnormal accumulation boundary for P consecutive sampling times (P≥5), it is determined to be an accumulation deviation;

[0052] The fracture risk assessment result is formed based on the deviation tracking results at continuous time points;

[0053] The method for obtaining the deviation value includes:

[0054] The deviations of force transfer, stagnation amplification, and recovery hysteresis are normalized using the normal fluctuation standard deviations of force transfer, stagnation amplification, and recovery hysteresis, respectively. The normalized deviations of force transfer, stagnation amplification, and recovery hysteresis are then weighted and summed according to preset weights to obtain the deviation value of the current workstation at the current sampling time.

[0055] As a further description of the above technical solution: the method for forming a fracture risk assessment result based on the deviation tracking results at continuous time intervals includes:

[0056] When all stations maintain normal deviation during continuous sampling, the output is in normal stretching state.

[0057] When a single workstation deviates from the warning alert, a fluctuation warning status is output.

[0058] When a single workstation experiences accumulated deviation, and the deviation of the stagnation and the deviation of the recovery hysteresis increase simultaneously, the risk accumulation status is output.

[0059] When K workstations accumulate deviations, and the deviation of the force transfer amount at each workstation increases sequentially from upstream to downstream along the tensile path, a high fracture risk state is output, where K≥2.

[0060] A fracture protection system for tensile testing of copper-clad steel wire, used to implement the aforementioned fracture protection method for tensile testing of copper-clad steel wire, the system comprising:

[0061] The state parameter sequence construction module is used to synchronously collect tensile characteristic parameters along the stretching path of copper-clad steel wire at each workstation, and construct a continuous state parameter sequence by combining the positional relationship of each workstation on the stretching path.

[0062] The force mapping sequence reconstruction module extracts the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount based on the continuous state parameter sequence, and reconstructs the force mapping sequence based on the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount.

[0063] The risk assessment result generation module establishes a risk evolution benchmark based on the stress mapping sequence and in combination with material batch and equipment type. It establishes the normal tensile fluctuation boundary and the abnormal accumulation boundary based on the risk evolution benchmark, obtains the deviation value at continuous sampling time, and compares and analyzes it with the normal tensile fluctuation boundary and the abnormal accumulation boundary to form a fracture risk assessment result.

[0064] The graded control module is used to control the tensile speed in a graded manner based on the fracture risk assessment results, so that the identified risk state can be reduced in advance before entering the high fracture risk state.

[0065] The beneficial effects of this application are as follows:

[0066] This application collects tension, current, running speed, vibration parameters and wire diameter changes synchronously at each work station along the stretching path of copper-clad steel wire, and constructs a continuous state parameter sequence by combining the position correlation relationship. This enables the unified association of running data from different work stations and different sampling times with the continuous stretching process of the same section of wire, thereby improving the ability to characterize the true stress state of the wire.

[0067] Furthermore, by extracting the force transfer amount, the amount of stagnation amplification, and the amount of recovery hysteresis, and reconstructing the force mapping sequence, continuous analysis can be performed on the load transfer between adjacent workstations, the fluctuation amplification caused by local operation stagnation, and the recovery hysteresis after the abnormal disturbance is removed. This enables effective identification of progressive risks before fracture. At the same time, by establishing a risk evolution benchmark by combining material batches and equipment types, and by classifying and controlling the stretching speed based on the risk assessment results, the risk accumulation state can be reduced in advance before the high fracture risk forms, thereby reducing the fracture probability and improving the stability and continuity of the stretching production process. Attached Figure Description

[0068] The present application will be further explained below with reference to the accompanying drawings and embodiments:

[0069] Figure 1 This is a flowchart of a method for preventing fracture during the stretching of copper-clad steel wire, provided in Embodiment 1 of this application.

[0070] Figure 2 This is a flowchart of a method for constructing a continuous sequence of state parameters provided in Embodiment 1 of this application;

[0071] Figure 3 This is a module connection diagram of a fracture protection system for copper-clad steel wire tensioning provided in Embodiment 2 of this application. Detailed Implementation

[0072] To make the technical means, inventive features, objectives, and effects of this application easier to understand, the application is further described below with reference to specific illustrations. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0073] Example 1, please refer to Figures 1-2 This application provides a technical solution: a method for preventing fracture during tensile testing of copper-clad steel wire, comprising:

[0074] Tensioning characteristic parameters are collected synchronously at each workstation along the stretching path of the copper-clad steel wire. A continuous state parameter sequence is constructed by combining the positional relationship of each workstation on the stretching path. The tensioning characteristic parameters include: tension, current, running speed, vibration parameters, and wire diameter change.

[0075] In some implementation methods, the implementation steps include:

[0076] Establish a unified path coordinate system in the operating direction of the copper-clad steel wire drawing production line. Number the wire feeding station, each drawing station, traction station and take-up station in sequence, and record the path position parameters of each collection point relative to the path start point, so that each type of status parameter corresponds to a clear station number and path position.

[0077] Secondly, status acquisition units are deployed at each corresponding workstation to collect tensile characteristic parameters. Specifically, this includes: tension acquisition units are set up between the pay-off station and the first tensile station, between adjacent tensile stations, and between the last tensile station and the take-up station to obtain the real-time tension of the wire in each section; current acquisition units are set up on the power supply circuit of each traction motor or drive motor to obtain the current at the corresponding workstation; speed acquisition units are set up on the rotation shaft of each traction wheel or take-up wheel to obtain the running speed of the wire as it passes through the corresponding workstation; vibration acquisition units are set up at the tensile die holder or transmission support to obtain the vibration response at the workstation; and wire diameter acquisition units are set up at the wire exit position to obtain the change in wire diameter after the corresponding pass.

[0078] All status acquisition units are connected to a unified acquisition controller, which outputs the same clock reference and synchronous trigger signal, enabling the tensile characteristic parameters to be acquired synchronously in the same sampling period, and adding a unified time identifier to the acquisition results of each station.

[0079] Based on the path distance between adjacent workstations and the running speed at the corresponding time, the transfer time of the wire from the previous workstation to the next workstation is determined. The status acquisition results of the previous and next workstations under the corresponding transfer time are matched so that the tensile characteristic parameters obtained from different workstations correspond to the continuous tensile process of the same wire.

[0080] Specifically, the matching process includes: accumulating the running distance within each sampling period according to the sampling order until the accumulated running distance reaches the path distance between adjacent workstations, and determining the corresponding time difference as the transmission time; then, adding the transmission time to the acquisition time of the previous workstation as the target matching time of the next workstation, reading the status acquisition result of the next workstation at the target matching time, thereby forming a matching data group of the same wire segment with the tensile characteristic parameters of the previous workstation at the original acquisition time and the tensile characteristic parameters of the next workstation at the target matching time, and recursively matching along multiple consecutive workstations so that the tensile characteristic parameters acquired by different workstations all correspond to the continuous tensile process of the same wire segment on the tensile path.

[0081] After location association is completed, the status acquisition results of each workstation are reorganized according to the path order and time order. Missing data are interpolated to fill in or remove. Data that does not fall into the same synchronous sampling period is identified as asynchronous edge data and is discarded or realigned according to a unified time identifier. The tensile characteristic parameters of the same wire section at each workstation are combined into a set of continuous state parameters, which are then arranged in order of sampling to construct a continuous state parameter sequence that reflects the stress change and workstation response relationship of the entire tensile process of copper-clad steel wire.

[0082] In this embodiment, by synchronously collecting tension, current, running speed, vibration parameters and wire diameter changes along the stretching path at each workstation, and constructing a continuous state parameter sequence by combining the positional correlation, the running information that was originally scattered at different workstations and different sampling times can be uniformly mapped to the continuous stretching process of the same section of wire, thereby improving the ability to characterize the true stress state of the wire and overcoming the problem of one-sided information caused by existing technologies that rely only on a single parameter or single-point detection.

[0083] Based on the continuous state parameter sequence, the force transfer quantity characterizing the load transmission relationship between adjacent workstations, the stagnation amplification quantity characterizing the amplification effect of local operation stagnation on load fluctuations, and the recovery hysteresis quantity characterizing the system recovery process after the abnormal disturbance is removed are extracted, and the force mapping sequence is reconstructed based on the force transfer quantity, stagnation amplification quantity, and recovery hysteresis quantity.

[0084] In some implementation methods, the implementation steps include:

[0085] Based on the continuous state parameter sequence, the continuous transfer process of the same wire segment between adjacent workstations is expanded, and an inter-workstation transfer analysis window is constructed. Specifically, according to the time identifier, workstation number, and path position parameters in the continuous state parameter sequence, the corresponding sampling intervals for the wire segment entering the previous workstation and arriving at the next workstation are determined. The tensile characteristic parameters of the previous workstation in the earlier sampling interval are aligned with the corresponding state values ​​of the next workstation in the later sampling interval, thereby obtaining the foundation for continuous inter-workstation analysis data for the same wire segment. This ensures that all subsequently extracted force characteristics are based on the continuous tensile process of the same physical object.

[0086] The method for extracting the force transfer amount includes: expanding the continuous transfer process of the same wire segment between adjacent workstations, constructing an inter-workstation transfer analysis window, identifying the output-side load change of the previous workstation and the receiving-side load change of the subsequent workstation based on the tensile characteristic parameter change sequence at continuous sampling times of the previous and subsequent workstations; when it is determined that the load changes of the previous and subsequent workstations have a temporal correspondence and their response lag is within the allowable transfer time range, the continuous sampling interval corresponding to the previous and subsequent workstations is determined as the effective response interval; and the force transfer amount is determined based on the duration of the effective response interval and the degree of exceeding the threshold of the difference of each tensile characteristic parameter. In some embodiments, the implementation steps include:

[0087] The speed difference sequence and wire diameter difference sequence are obtained at the previous station side during continuous sampling time, and the tension difference sequence and current difference sequence are obtained at the next station side during continuous sampling time.

[0088] Specifically, the method for obtaining the operating speed difference sequence, wire diameter difference sequence, tension difference sequence, and current difference sequence includes: under a unified sampling time reference, arranging the status acquisition results of the previous station and the next station in chronological order to form continuous sampling data; on the side of the previous station, sequentially reading the operating speed values ​​of two adjacent sampling times, and subtracting the operating speed value of the previous sampling time from the operating speed value of the next sampling time to obtain the operating speed difference of the corresponding sampling interval, and arranging them in chronological order to form the operating speed difference sequence.

[0089] Simultaneously, the wire diameter detection values ​​of two adjacent sampling times are read sequentially, and the wire diameter detection value of the previous sampling time is subtracted from the wire diameter detection value of the later sampling time to obtain the wire diameter difference of the corresponding sampling interval. The wire diameter difference is then arranged in chronological order to form a wire diameter difference sequence.

[0090] On the next workstation side, the tension value and drive motor current value of two adjacent sampling times are read sequentially. The tension difference and current difference between the next sampling time and the previous sampling time are calculated respectively, and arranged in chronological order to form a tension difference sequence and a current difference sequence. The difference retains the positive or negative sign and is used to characterize the direction of increase or decrease of the corresponding tensile characteristic parameter in the continuous sampling process. When only the fluctuation intensity needs to be evaluated later, the absolute value of the difference is taken or normalized.

[0091] When M consecutive (M≥3) differences in the running speed difference sequence are less than the preset speed change threshold, and M consecutive (M≥3) differences in the wire diameter difference sequence are less than the preset wire diameter change threshold, it is determined that there is a change in the output load of the previous station.

[0092] When multiple consecutive differences in the tension difference sequence are greater than a preset tension change threshold, and M consecutive differences (M≥3) in the current difference sequence are greater than a preset current change threshold, it is determined that there is a change in the receiving side load at the next workstation.

[0093] When the lag time between the start time of the load change on the receiving side of the subsequent station and the start time of the load change on the output side of the previous station is within the allowable transmission time range, the continuous sampling interval corresponding to the preceding and following stations is determined as the effective response interval, and the force transfer amount is determined based on the duration of the effective response interval and the degree of exceeding the threshold of the difference of each tensile characteristic parameter.

[0094] It should be noted that the preset speed change threshold, preset wire diameter change threshold, preset tension change threshold, preset current change threshold, and allowable transmission time range are all obtained statistically based on a benchmark sample set under normal tensile conditions. The benchmark sample set is preferably selected from normal operating data that is consistent with or similar to the material batch, equipment status, and environmental conditions corresponding to the current production task. After collecting the benchmark sample set, the differences in operating speed, wire diameter, tension, and current between adjacent sampling times are statistically analyzed to obtain the average level and fluctuation range of each difference sequence under normal conditions. Based on this, each threshold is set, so that the thresholds can reflect the true normal fluctuation boundaries of the current production line, rather than using fixed empirical values.

[0095] The preset speed change threshold is set as follows: Under normal tension conditions, the speed difference between adjacent sampling times at the same workstation is calculated to form a speed difference sample set; the mean and standard deviation of the speed difference sample set are calculated, and the preset speed change threshold is set as the mean speed difference minus the standard deviation of a preset multiple, and this threshold is negative. This setting is based on the fact that only when the decrease in operating speed significantly exceeds the lower limit of normal speed fluctuation is it identified as a change in effective load output, rather than ordinary speed regulation fluctuation. Preferably, the preset multiple is 2 to 3. Similarly, the preset wire diameter change threshold, preset tension change threshold, preset current change threshold, and allowable transmission time range are set.

[0096] The method for determining the force transfer amount based on the duration of the effective response interval and the degree of exceeding the threshold of the differences in each tensile characteristic parameter includes:

[0097] The number of sampling points within the effective response interval is counted and recorded as the number of consecutive effective sampling points. The duration of the effective response interval is obtained by multiplying the number of sampling points by the sampling period.

[0098] Within the effective response range, the operating speed difference and wire diameter difference of the previous station, and the tension difference and current difference of the next station are extracted respectively. The above tensile characteristic parameter differences are compared with the corresponding thresholds to obtain the excess range of each tensile characteristic parameter difference relative to the corresponding threshold.

[0099] Specifically, for the difference in operating speed and the difference in wire diameter, the excess amplitude below the corresponding negative threshold is extracted; for the difference in tension and the difference in current, the excess amplitude above the corresponding positive threshold is extracted.

[0100] The excess amplitude at each sampling time within the effective response interval is accumulated to obtain a comprehensive over-threshold quantity that characterizes the overall load transfer intensity of the effective response interval.

[0101] The duration and the comprehensive threshold quantity are normalized and then weighted and fused to obtain the force transfer quantity.

[0102] The greater the duration and the greater the overall over-threshold, the greater the force transfer, indicating that the load transfer between adjacent workstations is more stable and significant.

[0103] Preferably, the expression for the force transfer amount is:

[0104] In the formula, This is the amount of force transferred. The normalized duration. This is the normalized overall threshold value. and These are the weighting coefficients. It should be noted that the weighting coefficients in the formula are set by those skilled in the art based on actual circumstances or obtained through simulation with a large amount of data.

[0105] The method for obtaining the amount of delayed release is as follows:

[0106] Using the force transfer amount of the current workstation within the corresponding analysis period as the input transmission benchmark, the fluctuation amplitude of the tensile characteristic parameter corresponding to the workstation is extracted, and the fluctuation amplitude of the tensile characteristic parameter is normalized and then weighted and fused to obtain the actual fluctuation intensity.

[0107] Specifically, the method for obtaining the fluctuation amplitude of tensile characteristic parameters is as follows: within the analysis period corresponding to the current workstation, the tension, current, running speed, vibration parameters and wire diameter changes of the workstation are read in chronological order, forming tension time sequence sub-segments, current time sequence sub-segments, speed time sequence sub-segments, vibration time sequence sub-segments and wire diameter time sequence sub-segments respectively.

[0108] For each type of time series segment, the average or median value of each sampled value within that time series segment is first calculated and used as the local stable reference value of the corresponding tensile characteristic parameter within that analysis period.

[0109] Then, the deviation of each sampled value from the local stable reference value is calculated, and the absolute value of each deviation is taken to obtain the instantaneous fluctuation of the corresponding stretching characteristic parameter at each sampling time.

[0110] The maximum value among the instantaneous fluctuations is then selected as the fluctuation amplitude of the stretching characteristic parameter during the current analysis period.

[0111] Based on the force transfer amount of the current workstation in the corresponding analysis period, retrieve historical stable samples that match the force transfer amount under normal tensile conditions, and use the same calculation method as the actual fluctuation intensity to obtain the benchmark fluctuation intensity. It should be noted that the matching historical stable samples are those selected from historical normal production data that have the same workstation number, the same material batch identifier, the same equipment type identifier, and the force transfer amount is within the same preset force transfer range.

[0112] The actual fluctuation intensity is compared with the reference fluctuation intensity. When the actual fluctuation intensity is greater than the reference fluctuation intensity, the difference between the actual fluctuation intensity and the reference fluctuation intensity is determined as the stabilization and amplification amount. When the actual fluctuation intensity is less than or equal to the reference fluctuation intensity, the stabilization and amplification amount is recorded as zero.

[0113] The method for obtaining the recovery hysteresis includes: determining the time when the abnormal disturbance is resolved based on the changes in tension fluctuation amplitude, current fluctuation amplitude, vibration enhancement amplitude, running speed drop amplitude, and stagnation amplification amplitude at the current workstation during continuous sampling.

[0114] Based on the changes in the state parameters of the corresponding workstation and subsequent workstations after the abnormal disturbance is resolved, the time of recovery to stability is determined, and the time period between the time of the abnormal disturbance being resolved and the time of recovery to stability is denoted as the recovery to stability interval.

[0115] The recovery duration is determined based on the time length between the time when the abnormal disturbance is resolved and the time when stability is restored, and the recovery residual deviation is determined based on the difference between the state parameters after recovery and the stable state parameters before the disturbance.

[0116] The recovery hysteresis is determined based on the recovery duration and the recovery residual deviation.

[0117] In some implementation methods, the implementation steps include:

[0118] When the tension fluctuation amplitude, current fluctuation amplitude, and vibration enhancement amplitude decrease relative to the previous sampling time, the running speed drop amplitude decreases relative to the previous sampling time, and the stagnant discharge volume drops from above the normal fluctuation boundary corresponding to the stagnant discharge volume to within the normal fluctuation boundary corresponding to the stagnant discharge volume for M consecutive (M≥3) sampling times, the sampling time that first simultaneously meets the above conditions is determined as the abnormal disturbance release time.

[0119] From the moment the abnormal disturbance is resolved, the tension value, current value, running speed value, vibration value, and wire diameter change value of the corresponding workstation and subsequent workstations are continuously tracked. Each state parameter is compared with the stable reference range of the corresponding workstation under normal tension. When each state parameter returns to the corresponding stable reference range and does not exceed the corresponding stable reference range within the number of consecutive samples determined according to the sampling period and the allowable recovery confirmation time, the starting time of the continuous holding range is determined as the recovery stabilization time.

[0120] The stable reference interval is obtained statistically based on a benchmark sample set under normal tensile conditions. The benchmark sample set is selected from historical stable operating data that are consistent with or similar to the material batch, wire diameter, tensile pass, equipment status, and target operating speed corresponding to the current production task. The tension value, current value, operating speed value, vibration value, and wire diameter change value of each station in the benchmark sample set are statistically analyzed to obtain the stable center value and normal fluctuation amplitude of each state parameter under normal tensile conditions. The stable center value is used as the center of the interval, and the normal fluctuation amplitude is expanded according to a preset relaxation coefficient to form a stable reference interval for the corresponding state parameter.

[0121] The time length between the time when the abnormal disturbance is resolved and the time when stability is restored is defined as the recovery duration, i.e. the recovery stability interval. The difference between the average value of each state parameter within the recovery stability interval and the average value of the state parameters before the disturbance occurs is defined as the recovery residual deviation. The recovery hysteresis is determined based on the recovery duration and the recovery residual deviation.

[0122] The method for determining the recovery hysteresis based on the recovery duration and the recovery residual bias includes:

[0123] The current recovery duration is compared with the reference recovery duration corresponding to the historical stable sample under normal stretching conditions, or compared with the preset reference recovery duration, to obtain a dimensionless recovery duration evaluation value. The longer the recovery duration, the larger the recovery duration evaluation value, which is used to characterize the time delay of the system recovery process after the abnormal disturbance is removed.

[0124] The residual deviations corresponding to tension, current, operating speed, vibration, and wire diameter changes within the stable recovery range are compared with their respective reference deviation values ​​to obtain the individual residual deviation evaluation values ​​for each state parameter. Then, the individual residual deviation evaluation values ​​are weighted and fused to obtain the recovery residual deviation evaluation value. The larger the recovery residual deviation, the larger the recovery residual deviation evaluation value, which is used to characterize the degree of residual influence when the system is fully recovered after the abnormal disturbance is removed.

[0125] The recovery duration evaluation value and the recovery residual deviation evaluation value are weighted and fused according to a preset weight to obtain the recovery hysteresis. The recovery duration evaluation value is used to characterize the time lag of the recovery process, and the recovery residual deviation evaluation value is used to characterize the state residual offset after the recovery is completed. The two together characterize the degree of hysteresis and residual impact of the system recovery process after the abnormal disturbance is removed.

[0126] Furthermore, the recovery hysteresis is expressed as: .

[0127] in, To restore the hysteresis, To restore the historical evaluation value, To restore the residual deviation evaluation value, and These are the corresponding weights, and they satisfy... + =1.

[0128] It should be noted that the formulas mentioned above are all numerical calculations after removing dimensions. They are formulas that are closest to the real situation, obtained by software simulation based on a large amount of data. The weight coefficients in the formulas and the preset thresholds in the analysis process are set by those skilled in the art based on the actual situation or obtained by simulation based on a large amount of data.

[0129] The method for reconstructing the force mapping sequence based on the force transfer amount, the retardation amplification amount, and the recovery hysteresis amount includes:

[0130] Based on the correspondence of the same wire at each work station and at each sampling time, the force transfer amount, resistance amplification amount and recovery hysteresis amount corresponding to each work station at each sampling time are bound with the work station number, path position parameters and time identifier to form a force mapping unit.

[0131] Each force mapping unit is represented as: ;

[0132] in, Indicates the first The sampling time, the first The force mapping unit corresponding to each workstation This indicates the amount of force transferred at that location. This indicates the amount of stagnation at that location. This indicates the recovery hysteresis corresponding to this position.

[0133] Then, all the force mapping units are arranged according to the workstation order and time order to form a force mapping sequence.

[0134] In this embodiment, by extracting the force transfer amount, the amount of stagnation amplification, and the amount of recovery hysteresis, the load transfer relationship between adjacent workstations, the additional amplification effect of local operation stagnation on load fluctuations, and the degree of recovery hysteresis after the abnormal disturbance is removed can be characterized respectively. Based on this, the force mapping sequence can be reconstructed, so that the fracture risk is no longer only manifested in the form of a single moment exceeding the limit, but can be expressed as a dynamic evolution process combining path propagation, local amplification, and recovery residue, thereby significantly improving the ability to identify gradual anomalies before fracture.

[0135] Based on the stress mapping sequence, a risk evolution benchmark is established in combination with material batch and equipment type. The normal tensile fluctuation boundary and abnormal accumulation boundary are established according to the risk evolution benchmark. The deviation value at continuous sampling time is obtained and compared with the normal tensile fluctuation boundary and abnormal accumulation boundary to form a fracture risk judgment result.

[0136] In some implementation methods, the implementation steps include:

[0137] Obtain the material batch identifier and equipment type identifier corresponding to the current stretching task, and construct a benchmark matching label based on the material batch identifier and equipment type identifier. Based on the benchmark matching label, select force mapping sequence samples consistent with the current stretching task from historical normal production data to form a risk evolution benchmark sample set. The material batch identifier is used to characterize the raw material source and specification parameters of the current copper-clad steel wire. The equipment type identifier is used to characterize the station configuration, traction structure and drive control of the current stretching production line.

[0138] Based on the aforementioned risk evolution benchmark sample set, the force transfer amount, the amount of stagnation, and the amount of recovery hysteresis are statistically analyzed according to the work station number and sampling time. The benchmark center value and normal fluctuation range corresponding to each work station and each sampling time are obtained respectively. The benchmark center values ​​are arranged in chronological order and work station order to form a risk evolution benchmark sequence. The risk evolution benchmark sequence is used to characterize the normal evolution trajectory of the stress state of copper-clad steel wire during the advancement along the tensile path under the current material batch and equipment type conditions.

[0139] The normal stretching fluctuation boundary is established based on the aforementioned risk evolution benchmark. Specifically, the normal fluctuation range is defined by taking the benchmark center values ​​of the force transfer amount, the retardation amplification amount, and the recovery hysteresis amount corresponding to each work station and each sampling time as the center. The normal fluctuation range is defined by the standard deviation of the corresponding characteristic quantity. The corresponding normal fluctuation range is multiplied by a preset relaxation coefficient and then taken as the upper and lower deviation boundaries, forming the corresponding allowable deviation intervals.

[0140] An anomaly accumulation boundary is established based on historical anomaly samples. The material batch identifier and equipment type identifier corresponding to the current tensile task are obtained, and a benchmark matching label is constructed based on these identifiers. According to the benchmark matching label, force mapping sequence samples consistent with the current tensile task are selected from historical anomaly production data to form a risk evolution benchmark sample set. The deviation values ​​of force transfer, stagnation amplification, and recovery hysteresis corresponding to each workstation and sampling time within the continuous period before fracture are extracted, and their continuous deviation level and growth rate are statistically analyzed. Then, the offset interval that continuously deviates from the normal tensile fluctuation boundary and maintains an increasing trend is determined as the anomaly accumulation boundary, so that the anomaly accumulation boundary is located outside the normal tensile fluctuation boundary, used to characterize the critical range where the stress state transitions from normal fluctuation to continuous risk accumulation.

[0141] It should be noted that the method for determining the normal fluctuation range is as follows: extract historical normal sample values ​​of force transfer, stagnation amplification, and recovery hysteresis at each workstation and sampling stage, calculate their normal center level and normal dispersion range, and determine the numerical intervals around the normal center level and falling within the normal dispersion range as the normal fluctuation range; the normal center level is determined by statistically analyzing the mean or median value of the corresponding characteristic quantity at the same workstation and sampling stage in the historical normal samples; the normal dispersion range is determined by statistically analyzing the degree of dispersion of the corresponding characteristic quantity around the normal center level, and is used to form the boundary of the normal fluctuation range.

[0142] The abnormal accumulation boundary can be determined based on the statistical results of continuous deviation intervals in historical abnormal samples. Specifically, it involves extracting characteristic intervals from abnormal samples before fracture where multiple consecutive sampling times deviate from the normal fluctuation range and the degree of deviation continues to increase. The initial deviation level or overall deviation level of these continuous deviation intervals is statistically analyzed, and the statistical result that characterizes the starting position of continuous abnormal accumulation is determined as the abnormal accumulation boundary. This setting is based on the fact that when real-time characteristic quantities only briefly exceed the normal fluctuation range, it is usually an instantaneous disturbance; while when their real-time values ​​continuously reach the abnormal accumulation boundary and maintain an increasing trend, it indicates that the stress state has shifted from normal fluctuation to a state of continuous risk accumulation.

[0143] The real-time acquired force mapping sequence is compared with the corresponding risk evolution benchmark at each work station and time step. The deviation direction and deviation magnitude of the current force transfer amount, the amount of stagnation and the amount of recovery hysteresis relative to the corresponding benchmark center value are calculated respectively, and the deviation value at continuous sampling time is obtained.

[0144] The method for obtaining the deviation value includes:

[0145] The deviations mentioned above were normalized using the standard deviations of the normal fluctuations of the force transfer, the stagnation amplification, and the recovery hysteresis, respectively, to obtain the normalized deviations of the force transfer, stagnation amplification, and recovery hysteresis. Specifically, the normalized deviation of the force transfer was calculated by dividing the force transfer deviation by the standard deviation of the normal fluctuations of the force transfer; the normalized deviation of the stagnation amplification was calculated by dividing the stagnation amplification deviation by the standard deviation of the normal fluctuations of the stagnation amplification; and the normalized deviation of the recovery hysteresis was calculated by dividing the recovery hysteresis deviation by the standard deviation of the normal fluctuations of the recovery hysteresis. The deviation was the absolute value of the offset.

[0146] Among them, the normal fluctuation standard deviation of force transfer, retardation amplification and recovery hysteresis is obtained based on the statistical analysis of historical stable samples under normal tensile conditions.

[0147] The normalized deviations of force transfer, retardation amplification, and recovery hysteresis are weighted and summed according to preset weights to obtain the deviation value of the current workstation at the current sampling time. The preset weights are determined based on the contribution of force transfer, retardation amplification, and recovery hysteresis to the characterization of fracture risk. Historical production data is first selected as the weight calibration sample, including normal tensile samples, early warning tensile samples, and abnormal samples before fracture. The normalized deviations of force transfer, retardation amplification, and recovery hysteresis in each sample are calculated, and the degree of differentiation between normal and abnormal samples is statistically analyzed. If a certain normalized deviation significantly increases in abnormal samples but fluctuates little in normal samples, and its deviation from the normal range occurs before the fracture or high-risk determination time, then the normalized deviation is considered to have a high contribution to fracture risk and is assigned a larger weight.

[0148] When the deviation value is within the normal stretching fluctuation boundary, it is judged as normal deviation; when the deviation value exceeds the normal stretching fluctuation boundary but does not enter the abnormal accumulation boundary, it is judged as warning deviation; when the deviation value enters the abnormal accumulation boundary for P consecutive sampling times (P≥5), it is judged as accumulation deviation.

[0149] A fracture risk assessment result is generated based on the deviation tracking results at continuous time intervals. Specifically, when all stations maintain normal deviation at continuous sampling time intervals, a normal tensile state is output.

[0150] When a single workstation experiences a warning deviation but does not form a continuous expansion, a fluctuation warning status is output; when a single workstation experiences an accumulated deviation, and the deviation of the amount of stagnation and the deviation of the amount of recovery hysteresis increase simultaneously, a risk accumulation status is output.

[0151] When K workstations accumulate deviations, and the deviation of the force transfer amount at each workstation increases sequentially from upstream to downstream along the tensile path, a high fracture risk state is output, where K≥2.

[0152] Based on the fracture risk assessment results, the tensile speed is controlled in stages to reduce the identified risk state in advance before it enters the high fracture risk state.

[0153] It should be noted that the higher the risk level, the greater the reduction in stretching speed. When the first risk level is detected... When a workstation outputs a risk accumulation status, an instruction to reduce the stretching speed is immediately executed to decrease the stretching speed of the current workstation. Optionally, the speed can be reduced by 10%-25% of the current speed.

[0154] In this embodiment, a risk evolution benchmark is established by combining material batches and equipment types, and the normal tensile fluctuation boundary and abnormal accumulation boundary are established accordingly. This allows the risk judgment basis to match the current production conditions, avoiding the problem that the fixed threshold control method is not adaptable to different materials and different equipment operating conditions. This helps to reduce the false alarm rate and the missed alarm rate, and improve the accuracy and stability of fracture risk judgment.

[0155] Furthermore, by tracking the degree of deviation at continuous moments and implementing graded control of the stretching speed after identifying the risk accumulation state, the risk state can be reduced in advance before entering the high fracture risk state. This transforms the traditional passive protection method based on shutdown or critical alarm after fracture into an active intervention method for the risk accumulation stage. This not only helps to reduce the probability of copper-clad steel wire fracture during the stretching process, reduce downtime losses and scrap rate, but also helps to improve the operational stability and production continuity of the entire stretching production line.

[0156] Example 2, please refer to Figure 3 This application provides a technical solution: a fracture prevention protection system for copper-clad steel wire under tension, which is used to implement the aforementioned fracture prevention protection method for copper-clad steel wire under tension. The system includes:

[0157] The state parameter sequence construction module synchronously collects tensile characteristic parameters along the stretching path of copper-clad steel wire at each workstation, and constructs a continuous state parameter sequence by combining the positional relationship of each workstation on the stretching path.

[0158] The force mapping sequence reconstruction module extracts the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount based on the continuous state parameter sequence, and reconstructs the force mapping sequence based on the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount.

[0159] The risk assessment result generation module establishes a risk evolution benchmark based on the stress mapping sequence and the material batch and equipment type. Based on the risk evolution benchmark, it establishes the normal tensile fluctuation boundary and the abnormal accumulation boundary, obtains the deviation value at continuous sampling time, and compares and analyzes it with the normal tensile fluctuation boundary and the abnormal accumulation boundary to form a fracture risk assessment result.

[0160] The graded control module, in conjunction with the fracture risk assessment results, performs graded control on the tensile speed, so that the identified risk state is reduced in advance before entering the high fracture risk state.

[0161] The foregoing has shown and described the basic principles, main features, and advantages of this application. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this application. Various changes and modifications can be made to this application without departing from the spirit and scope thereof, and all such changes and modifications fall within the scope of this application as claimed. The scope of protection of this application is defined by the appended claims and their equivalents.

Claims

1. A method for preventing breakage during tensile testing of copper-clad steel wire, characterized in that, include: Along the stretching path of copper-clad steel wire, stretching characteristic parameters are collected synchronously at each workstation, and a continuous state parameter sequence is constructed by combining the positional relationship of each workstation on the stretching path. Based on the continuous state parameter sequence, the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount are extracted, and the force mapping sequence is reconstructed based on the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount. A risk evolution benchmark is established by combining material batches and equipment types. Based on the risk evolution benchmark, the normal tensile fluctuation boundary and the abnormal accumulation boundary are established. Based on the force mapping sequence and the comparison and analysis of the normal tensile fluctuation boundary and the abnormal accumulation boundary, a fracture risk judgment result is formed. Based on the fracture risk assessment results, the tensile speed is controlled in stages to reduce the identified risk state in advance before it enters the high fracture risk state.

2. The method for preventing breakage during tensile testing of copper-clad steel wire according to claim 1, characterized in that, Methods for constructing continuous state parameter sequences include: In the operating direction of the copper-clad steel wire drawing production line, the wire feeding station, each drawing station, traction station and take-up station are numbered sequentially. Status acquisition units are deployed at each corresponding workstation to collect tensile characteristic parameters; Based on the path distance between adjacent workstations and the corresponding running speed at the time, determine the transfer time of the wire from the previous workstation to the next workstation. The status acquisition results of the front and rear workstations at the corresponding transfer time are matched so that the tensile characteristic parameters acquired by different workstations correspond to the continuous tensile process of the same wire. The tensile characteristic parameters of the same wire at each workstation are combined into a set of continuous state parameters, which are then arranged in order of sampling to construct a continuous state parameter sequence.

3. The method for preventing breakage during tensile testing of copper-clad steel wire according to claim 1, characterized in that, The method for extracting the force transfer amount includes: The continuous transfer process of the same wire segment between adjacent workstations is expanded, and an inter-workstation transfer analysis window is constructed. Based on the change sequence of tensile characteristic parameters at continuous sampling times of the previous and subsequent workstations, the output-side load change of the previous workstation and the receiving-side load change of the subsequent workstation are identified. When it is determined that the load changes of the preceding and following workstations have a temporal correspondence and their response lag is within the allowable transmission time range, the continuous sampling intervals corresponding to the preceding and following workstations are determined as the effective response intervals. The amount of force transfer is determined based on the duration of the effective response interval and the difference between each tensile characteristic parameter.

4. The method for preventing breakage during tensile testing of copper-clad steel wire according to claim 3, characterized in that, Methods for determining the amount of force transfer include: The number of sampling points within the effective response interval is counted, and the duration of the effective response interval is obtained by multiplying the number of sampling points by the sampling period. Within the effective response range, the operating speed difference and wire diameter difference of the previous station and the tension difference and current difference of the next station are extracted, and the above tensile characteristic parameter differences are compared with the corresponding thresholds to obtain the excess range of each tensile characteristic parameter difference relative to the corresponding threshold. The excess values ​​are accumulated to obtain a comprehensive over-threshold value. The duration and comprehensive over-threshold value are normalized and then weighted and fused to obtain the force transfer value.

5. A method for preventing breakage during tensile testing of copper-clad steel wire according to claim 1, characterized in that, The method for obtaining the amount of delayed release is as follows: Using the force transfer amount of the current workstation in the corresponding analysis period as the input transmission benchmark, the fluctuation amplitude of the tensile characteristic parameter corresponding to the workstation is extracted, and the fluctuation amplitude of the tensile characteristic parameter is normalized and then weighted and fused to obtain the actual fluctuation intensity. Based on the force transfer amount of the current workstation in the corresponding analysis period, retrieve historical stable samples that match the force transfer amount under normal tensile conditions, and use the same calculation method as the actual fluctuation intensity to obtain the benchmark fluctuation intensity. The actual fluctuation intensity is compared with the reference fluctuation intensity. When the actual fluctuation intensity is greater than the reference fluctuation intensity, the difference between the two is determined as the stabilizing amplification amount. When the actual fluctuation intensity is less than or equal to the reference fluctuation intensity, the stabilizing amplification amount is recorded as zero.

6. The method for preventing breakage during tensile testing of copper-clad steel wire according to claim 1, characterized in that, The method for obtaining the recovery hysteresis includes: Based on the changes in tension fluctuation amplitude, current fluctuation amplitude, vibration enhancement amplitude, running speed reduction amplitude, and stagnation discharge amplitude at the current workstation during continuous sampling, the time for the abnormal disturbance to be resolved is determined. Based on the changes in the state parameters of the corresponding workstation and subsequent workstations after the time when the abnormal disturbance is removed, the time when the stability is restored is determined, and the stability interval is obtained. The recovery duration is determined based on the time length between the time when the abnormal disturbance is resolved and the time when stability is restored, and the recovery residual deviation is determined based on the difference between the state parameters after recovery and the stable state parameters before the disturbance. The recovery hysteresis is determined based on the recovery duration and the recovery residual deviation.

7. A method for preventing breakage during tensile testing of copper-clad steel wire according to claim 6, characterized in that, The method for determining the recovery hysteresis based on the recovery duration and the recovery residual bias includes: The current recovery time is compared with the reference recovery time corresponding to the historical stable sample under normal stretching conditions to obtain the recovery time evaluation value. The residual deviations corresponding to the tensile characteristic parameters within the recovery stable range are compared with their respective reference deviation values ​​to obtain the individual residual deviation evaluation quantity for each tensile characteristic parameter. The residual deviation evaluation values ​​of each individual item are weighted and fused to obtain the recovery residual deviation evaluation value; The recovery duration evaluation value and the recovery residual deviation evaluation value are weighted and fused according to a preset weight to obtain the recovery hysteresis.

8. A method for preventing breakage during tensile testing of copper-clad steel wire according to claim 1, characterized in that, The method for reconstructing the force mapping sequence based on the force transfer amount, the retardation amplification amount, and the recovery hysteresis amount includes: Based on the correspondence of the same wire segment at each workstation and sampling time, the force transfer, retardation amplification, and recovery hysteresis corresponding to each workstation at each sampling time are bound to the workstation number, path location parameters, and time identifier to form a force mapping unit: All force mapping units are arranged according to workstation order and time order to form a force mapping sequence.

9. A method for preventing breakage during tensile testing of copper-clad steel wire according to claim 1, characterized in that, Methods for establishing the boundaries between normal stretching fluctuations and abnormal accumulation include: Obtain the material batch identifier and equipment type identifier corresponding to the current stretching task to construct a benchmark matching label. Based on the benchmark matching label, select force mapping sequence samples that are consistent with the current stretching task from historical normal production data to form a risk evolution benchmark sample set. Based on the risk evolution benchmark sample set, the force transfer amount, the amount of stagnation and the amount of recovery hysteresis are statistically analyzed according to the work station number and the sampling time. The benchmark center value and normal fluctuation range corresponding to each work station and each sampling time are obtained respectively. The benchmark center values ​​are arranged in time order and work station order to form a risk evolution benchmark sequence. The normal stretching fluctuation boundary is established based on the aforementioned risk evolution benchmark; Establish anomaly accumulation boundaries based on historical anomaly samples.

10. A method for preventing breakage during tensile testing of copper-clad steel wire according to claim 1, characterized in that, The fracture risk assessment results include normal tensile state, fluctuation warning state, risk accumulation state, and high fracture risk state.

11. A method for preventing breakage during tensile testing of copper-clad steel wire according to claim 10, characterized in that, The methods for determining fracture risk include: The real-time acquired force mapping sequence is compared with the corresponding risk evolution benchmark at each work station and time step. The deviation direction and deviation magnitude of the current force transfer amount, the amount of stagnation and the amount of recovery hysteresis relative to the corresponding benchmark center value are calculated respectively, and the deviation value at continuous sampling time is obtained. When the deviation value is within the normal stretching fluctuation boundary, it is judged as a normal deviation; When the deviation value exceeds the normal stretching fluctuation boundary but does not enter the abnormal accumulation boundary, it is judged as a warning deviation; When the deviation value enters the abnormal accumulation boundary for P consecutive sampling times, it is determined to be an accumulation deviation. The fracture risk assessment result is formed based on the deviation tracking results at continuous time intervals.

12. A method for preventing breakage during tensile testing of copper-clad steel wire according to claim 11, characterized in that, Methods for determining fracture risk based on deviation tracking results at consecutive time points include: When all stations maintain normal deviation during continuous sampling, the output is in normal stretching state. When a single workstation deviates from the warning alert, a fluctuation warning status is output. When a single workstation experiences accumulated deviation, and the deviation of the stagnation and the deviation of the recovery hysteresis increase simultaneously, the risk accumulation status is output. When K workstations accumulate deviations, and the deviation of the force transfer amount at each workstation increases sequentially from upstream to downstream along the tensile path, a high fracture risk state is output, where K≥2.

13. A fracture protection system for tensile testing of copper-clad steel wire, used to implement the fracture protection method for tensile testing of copper-clad steel wire as described in any one of claims 1-12, characterized in that, The system includes: The state parameter sequence construction module is used to synchronously collect tensile characteristic parameters along the stretching path of copper-clad steel wire at each workstation, and construct a continuous state parameter sequence by combining the positional relationship of each workstation on the stretching path. The force mapping sequence reconstruction module extracts the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount based on the continuous state parameter sequence, and reconstructs the force mapping sequence based on the force transfer amount, the stagnation amplification amount, and the recovery hysteresis amount. The risk assessment result generation module establishes a risk evolution benchmark based on the stress mapping sequence and in combination with material batch and equipment type. It establishes the normal tensile fluctuation boundary and the abnormal accumulation boundary based on the risk evolution benchmark, obtains the deviation value at continuous sampling time, and compares and analyzes it with the normal tensile fluctuation boundary and the abnormal accumulation boundary to form a fracture risk assessment result. The graded control module is used to control the tensile speed in a graded manner based on the fracture risk assessment results, so that the identified risk state can be reduced in advance before entering the high fracture risk state.

Images