A method for continuous batch processing of partially twisted busbars

Abstract

This application relates to a method for continuous batch processing of partially twisted cabling. The cabling includes multiple cores arranged side-by-side, with adjacent cores forming a pairing group. Adjacent pairing groups form twisted units with opposite twisting directions within a partially twisted section. The method determines a preset twisting direction based on the arrangement order of the pairing groups and defines a stable twisting zone and a phase recovery zone within the partially twisted section. It generates boundary clearance constraints based on adjacent boundaries and generates closed reset constraints based on the target thread sequence of subsequent straight sections. While maintaining the stable twisting zone and satisfying the boundary clearance constraints, it determines the parameters of the phase recovery zone and controls the twisting actuator and traction actuator to perform hot pressing and shaping after phase recovery. This application can balance the misalignment clearance of adjacent twisted units and the reset of the thread sequence and pitch of subsequent straight sections, improving the stability of continuous batch processing.

Description

Technical Field

[0001] This application relates to the field of cabling processing technology, and in particular to a method for continuous batch processing of partially twisted cabling. Background Technology

[0002] Ribbon cables typically consist of multiple wires arranged side-by-side along their width. These wires maintain a straight, parallel arrangement along their length to facilitate connector crimping, mating, soldering, or internal wiring within equipment. In some signal transmission scenarios, to mitigate crosstalk between adjacent wires or external interference, some wires in the ribbon cable are processed into partially twisted pairs, creating straight sections and partially twisted sections along the cable's length.

[0003] For a partially twisted cabling, two adjacent cores form a pairing group, and each pairing group forms a twisted unit within the partially twisted section. Furthermore, two adjacent twisted units along the width direction have opposite twisting directions. This structure requires both the formation of a stable twisted configuration within the partially twisted section and the restoration of the parallel straight-line state of multiple cores within the straight section to ensure the stability of the wiring sequence and pitch at subsequent termination positions.

[0004] However, in continuous batch processing, if local twisted segments are formed only according to fixed twist pitch and fixed exit position, two mutually restrictive problems can easily arise: On the one hand, adjacent twisted units with opposite twist directions need to be staggered within the local twisted segment to reduce local congestion or width fluctuations caused by the close proximity of wire cores at adjacent boundaries; on the other hand, after exiting the twisted segment, the pairing group needs to be restored to the target wire sequence and target pitch of the subsequent straight-line segment. If the twisting phase of the entire local twisted segment is directly adjusted to meet the straight-line reset, it may disrupt the staggered state of adjacent twisted units within the local twisted segment; if only the staggered twisting state within the local twisted segment is guaranteed, it may lead to instability in the wire sequence or pitch of the wire cores in the subsequent straight-line segment after exiting the twisted segment.

[0005] Therefore, it is necessary to provide a continuous batch processing method that can take into account both the misalignment and repositioning requirements of adjacent twisted units within a local twisted section and the subsequent closure and reset requirements of the straight section. Summary of the Invention

[0006] This application provides a method for continuous batch processing of partially twisted cabling. The main technical problem it solves is how to restore the stranded cores to the target wire sequence and target pitch of the subsequent straight section while maintaining the staggered arrangement of adjacent reverse twisted units within the partially twisted section.

[0007] To solve the above-mentioned technical problems, this application provides a method for continuous batch processing of partially twisted ribbon cables. The ribbon cable includes multiple cores arranged side by side along the width direction, with adjacent cores forming a pairing group. The ribbon cable has a partially twisted section along the length direction and a subsequent straight section located on the out-of-twist side of the partially twisted section. Adjacent pairing groups are respectively used to form twisted units with opposite twisting directions within the partially twisted section, including: S10. Determine the corresponding preset twisting direction according to the arrangement order of each pairing group, and determine a stable twisting area and a phase recovery area located on the outgoing side of the stable twisting area within the local twisting segment; wherein, the stable twisting area is used to enable multiple pairing groups to form a continuous twisting unit with the corresponding preset twisting direction. S20. Generate boundary clearance constraints based on the adjacent boundaries between two adjacent twisted units, and generate closed reset constraints based on the target line sequence of the subsequent straight segments. S30. While ensuring that the stable twisted pair satisfies the boundary yielding constraint, determine the phase recovery zone parameters according to the closed reset constraint; S40. According to the preset twisting direction control, the twisting actuator performs partial twisting processing on the multiple continuously transmitted wire cores, and controls the traction actuator and / or the twisting actuator according to the phase recovery zone parameters, so that the pairing group completes the twisting phase recovery in the phase recovery zone, and then performs hot pressing and shaping on the multiple wire cores.

[0008] More preferably, the local twisted section includes, along its length, the stable twisted region and the phase recovery region, with the phase recovery region located between the stable twisted region and the subsequent straight section; The stable twisting zone is used to enable multiple pairing groups to form a continuous twisting structure with a target twisting pitch according to the corresponding preset twisting direction, and the phase recovery zone is used to enable at least some of the pairing groups to transition from a twisting phase that satisfies the boundary yielding constraint to a twisting phase that satisfies the closed reset constraint.

[0009] More preferably, the adjacent boundary is located between two adjacent twisted pairs along the width direction, and each side of the adjacent boundary has a boundary side wire core, which is a wire core in the twisted pair that is closer to the adjacent boundary. The boundary clearance constraint includes: the length direction positions of the boundary side line cores on both sides of the same adjacent boundary reach the local minimum distance from the adjacent boundary, and are offset along the length direction of the wiring by a distance not less than a preset clearance distance.

[0010] More preferably, the preset clearance distance is determined based on the target twist pitch of the twisted pair unit within the stable twisted pair zone, and the preset clearance distance is 1 / 4 to 3 / 4 of the target twist pitch; Within the stable twisted zone, two adjacent twisted units form a staggered twisted structure with a continuous twisting cross cycle of no less than two twisting cycles according to the preset clearance distance.

[0011] More preferably, the target line sequence is the target arrangement order of the multiple wire cores along the width direction in the subsequent straight section; The closed reset constraint includes: after each pairing group is twisted out, the two cores in each pairing group are restored to the width direction sequence corresponding to the target line sequence, and the center distance between adjacent cores in the subsequent straight section is within the allowable range of the target pitch.

[0012] More preferably, determining the phase recovery zone parameters based on the closed reset constraint includes: determining the exit phase of the pairing group reaching the exit side of the stable twisted zone when the boundary yielding constraint is satisfied, based on the preset target twist pitch of the stable twisted zone, the preset length of the stable twisted zone, and the preset twist direction of each pairing group. The phase exiting the zone is compared with the reset phase corresponding to the closed reset constraint, and when the difference between the two exceeds the preset phase allowable range, the difference is determined as the phase difference to be recovered.

[0013] More preferably, before determining the phase recovery zone parameters, the length of the stable twisted zone is adjusted within the preset allowable range of the stable twisted zone length according to one twisted cycle, half a twisted cycle, or a preset cycle unit corresponding to the target twisted pitch of the stable twisted zone, so that the adjusted exit phase is close to the reset phase, and the remaining phase difference after adjustment is taken as the remaining phase difference to be recovered.

[0014] More preferably, the phase recovery area is divided into multiple recovery segments along the length direction, and each recovery segment corresponds to a segment length, a local target pitch, and a unit phase adjustment amount in the processing formula; Along the direction from the stable twisted pair area to the subsequent straight section, the unit phase adjustment amount corresponding to the plurality of the recovery sub-segments is sequentially applied to at least a portion of the pairing groups, so that the twisted phase of the at least a portion of the pairing groups gradually approaches the reset phase, and the sum of the unit phase adjustment amounts of the plurality of recovery sub-segments corresponds to the remaining phase difference to be recovered.

[0015] More preferably, during partial twisting processing, the twisting actuator performs twisting action on multiple paired groups according to the preset twisting direction; When the wire core enters any of the recovery segments, the traction actuator pulls the wire core according to the segment length corresponding to the recovery segment, and the twisting actuator adjusts the twisting angular velocity or the number of twisting rotations according to the local target twisting pitch corresponding to the recovery segment, so that the unit length twisting phase change within the recovery segment corresponds to the unit phase adjustment amount.

[0016] More preferably, after the pairing group passes through the phase recovery zone, the multiple wire cores are guided into the subsequent straight section by a guiding mechanism, and the width spacing of adjacent wire cores is limited by a spacing keeping mechanism, so that the multiple wire cores maintain the target wire sequence and target pitch in the subsequent straight section; After the guiding mechanism and / or the spacing mechanism, the multiple core wires are hot-pressed and shaped by the hot pressing mechanism so that the wiring remains in a straight parallel state in the subsequent straight section and the local twisted section remains in a shaped state where the adjacent twisted units have opposite twisting directions.

[0017] Compared with the prior art, this application has at least the following beneficial effects: This application sets up a stable twisted pair region and a phase recovery region within a local twisted pair segment. The stable twisted pair region is used to satisfy the boundary clearance constraints between adjacent twisted pair units, while the phase recovery region is used to satisfy the closed reset constraints of subsequent straight-line segments. This avoids directly disturbing the twisted pair phase in the stable twisted pair region to satisfy the line sequence reset of subsequent straight-line segments, thereby reducing the risk of local congestion or width fluctuations caused by adjacent twisted pair units being too close together at adjacent boundaries.

[0018] Meanwhile, this application generates closed-loop reset constraints based on the target wire sequence of subsequent straight sections, and uses phase recovery zone parameters to gradually transition the paired group to the twisted phase that satisfies the closed-loop reset constraints before stranding. This improves the stability of restoring the target wire sequence and target pitch of multiple cores after stranding, reducing the risks of wire sequence misalignment, pitch fluctuations, and unstable termination in subsequent straight sections.

[0019] Furthermore, this application allows for the phase recovery process to be completed in segments by gradually adjusting the local target pitch or unit phase adjustment amount through multiple recovery sub-segments, thus avoiding abrupt phase adjustments at the end of local twisted segments. Subsequent guiding, spacing maintenance, and hot-pressing shaping further maintains the parallel straight-line state of the straight segments and the opposite twisting direction of adjacent twisted units within the local twisted segments. Attached Figure Description

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

[0021] Figure 1 This is a schematic diagram of the structure of a partial twisted-pair cabling in one embodiment of this application; Figure 2 This is a flowchart of a continuous batch processing method according to an embodiment of this application; Figure 3 This is a physical reference drawing of a partial twisted-pair ribbon cable product according to an embodiment of this application; Figure 4 This is a physical reference diagram showing a partial twisted-pair cabling being processed on a processing equipment according to an embodiment of this application; Figure 5 This is a physical reference diagram of the wire guide and twisting processing part of a partial twisted-pair cable processing equipment in one embodiment of this application; Figure 6 This is a physical reference diagram showing the conveying state of the cabling or partially twisted cabling to be processed in the processing equipment according to one embodiment of this application; Figure 7 This is a physical reference diagram of a partial twisted-pair cable processing equipment and a manual debugging scene in one embodiment of this application.

[0022] It should be noted that, Figures 3 to 7 The physical reference drawings are intended to illustrate the form and processing scenarios of partial twisted-pair ribbon cable products and do not constitute a limitation on the scope of protection of this application.

[0023] Explanation of reference numerals in the attached figures 100. Partial twisted pair cabling; 10. Core wire; 11. Pairing group; 12. Boundary side core wire; 110. Straight section; 111. Preceding straight section; 112. Subsequent straight section; 120. Partial twisted pair section; 121. Stable twisted pair area; 122. Phase recovery area; 123. Recovery sub-segment; 130. Twisted pair unit; 140. Adjacent boundary; L, length direction; W, width direction. Detailed Implementation

[0024] The embodiments of this application will be described in detail below. It should be understood that the following embodiments are used to illustrate the technical solution of this application and are not intended to limit the scope of protection of this application. Unless otherwise stated, in this embodiment, the length direction L refers to the direction in which the partially twisted busbar 100 is continuously transmitted, and the width direction W refers to the direction in which the multiple wire cores 10 are arranged side by side.

[0025] See Figures 1-7This specific embodiment provides a continuous batch processing method for partially twisted cabling, mainly used to solve the problem of mutual restraint between adjacent reverse twisted units 130 needing to be misaligned within a partial twisted section 120, and needing to restore the target thread sequence and target pitch of the subsequent straight section 112 after untwisting. By distinguishing a stable twisted area 121 and a phase recovery area 122 within the partial twisted section 120, the stable twisted area 121 is mainly used to maintain the boundary yielding relationship between adjacent twisted units 130, and the phase recovery area 122 is mainly used to absorb the phase difference between the phase exiting the area and the reset phase. Thus, without destroying the misaligned twisted state of the stable twisted area 121, the stability of the thread sequence and pitch reset of the subsequent straight section 112 is improved.

[0026] In one embodiment, the partially twisted ribbon cable 100 includes multiple cores 10 arranged side-by-side along the width direction W, with adjacent cores 10 forming a pairing group 11. The partially twisted ribbon cable 100 has a straight section 110 and a partially twisted section 120 along the length direction L. The straight section 110 includes a preceding straight section 111 located on the twist-in side of the partially twisted section 120, and a subsequent straight section 112 located on the twist-out side of the partially twisted section 120. Within the preceding straight section 111 and the subsequent straight section 112, the multiple cores 10 maintain a straight, side-by-side arrangement to facilitate connector crimping, insertion, soldering, or other termination operations. Within the partially twisted section 120, each pairing group 11 forms a twisted unit 130, and the twisting directions of two adjacent twisted units 130 along the width direction W are opposite.

[0027] Before continuous batch processing, a processing formula can be established based on the specifications of the products to be processed. The processing formula should at least record the number of wire cores 10, the target arrangement order of each wire core 10 in the width direction W, the division method of the pairing groups 11, the preset stranding direction of each pairing group 11, the target length of the local twisted section 120, the target strand pitch P of the stable twisted area 121, the target thread sequence of the subsequent straight section 112, the allowable range of the target pitch of the subsequent straight section 112, and the hot pressing and shaping position. The processing equipment can continuously move multiple wire cores 10 along the length direction L by traction actuator, and establish the position reference of the length direction L by encoder pulse count, traction wheel rotation count, or feeding cycle. The twisting actuator performs twisting action on the corresponding pairing group 11 according to the processing formula. The guiding mechanism and the spacing mechanism are used to guide the twisted wire cores 10 into the subsequent straight section 112, and the hot pressing mechanism is used to hot press and shape the formed local twisted wire 100.

[0028] The traction actuator may include a traction wheel, traction gripper, synchronous belt traction assembly, or other mechanism capable of traction of the wire core 10 according to a set length. The twisting actuator may include a rotating clamping member, a rotating wire-pulling member, a paired twisting clamp, or other mechanism capable of causing two wire cores 10 within the same pairing group 11 to intertwine. The guiding mechanism may include a guide groove, a wire-separating guide member, a guide plate, or a guide wheel. The spacing mechanism may include a comb member, a spacing groove, a pressure plate, or a limiting block. The hot pressing mechanism may include a hot pressing roller, a hot pressing plate, or pressing members arranged vertically opposite each other. The above mechanisms may be arranged on the same continuous processing equipment or on multiple stations of a continuous production line.

[0029] Based on the above-mentioned processing object, processing formula, and actuator, the continuous batch processing method of this embodiment can be implemented according to the following steps.

[0030] In S10, the corresponding preset twisting direction is determined according to the arrangement order of each pairing group 11, and a stable twisting zone 121 and a phase recovery zone 122 located on the outgoing side of the stable twisting zone 121 are determined within the local twisting section 120.

[0031] Specifically, when determining the preset twist direction, multiple pairing groups 11 can be numbered sequentially according to the width direction W, and then the twist direction of each pairing group 11 can be determined according to the number. For example, the 1st, 3rd, and 5th pairing groups 11 are determined as the first type of pairing groups, and the first type of pairing groups form a twisted pair unit with the first twist direction within the local twisted pair section 120; the 2nd, 4th, and 6th pairing groups 11 are determined as the second type of pairing groups, and the second type of pairing groups form a twisted pair unit with the second twist direction within the local twisted pair section 120, with the first twist direction being opposite to the second twist direction. Thus, two adjacent pairing groups 11 along the width direction W can form a twisted pair unit 130 with opposite twist directions. The above odd-even numbering method is only one implementation method. In other implementation methods, the preset twist direction of each pairing group 11 can also be determined according to the number of wire cores, the signal pair allocation relationship, the termination order, or the product specifications.

[0032] When determining the stable twisted pair region 121 and the phase recovery region 122, the starting and ending positions of the local twisted pair segment 120 in the length direction L can be determined first according to the product specifications. Then, the stable twisted pair region 121 for forming a continuous twisted structure and the phase recovery region 122 located on the out-of-twist side of the stable twisted pair region 121 are divided from the local twisted pair segment 120. The stable twisted pair region 121 is used to enable multiple pairing groups 11 to form a continuous twisted unit 130 under the target twist pitch P according to the corresponding preset twisting direction. The phase recovery region 122 is located between the stable twisted pair region 121 and the subsequent straight section 112, and is used to enable at least some pairing groups 11 to gradually transition from a twisted phase that satisfies the boundary clearance constraint to a twisted phase that satisfies the closed reset constraint.

[0033] Both the stable twisting zone 121 and the phase recovery zone 122 are processing sections divided along the length direction L. Their boundaries can be determined by the traction length, encoder pulse count, entry position, exit position, or number of twisting rotations in the processing formula, and it is not required that the processing equipment must have an independent physical structure corresponding to each of their names. The length of the stable twisting zone 121 preferably satisfies multiple complete twisting cross cycles to ensure a continuous and stable twisting pattern within the local twisting segment 120. The length of the phase recovery zone 122 can be determined based on the phase difference to be recovered, the allowable range of local target twist pitch variation, and the line sequence reset requirements of the subsequent straight section 112. The recovery sub-segment 123 described below is a sub-segment further divided along the length direction L within the phase recovery zone 122.

[0034] In this embodiment, the stable twisted pair zone 121 and the phase recovery zone 122 are provided to separate the stable misaligned twisting function within the local twisted pair section 120 from the wire sequence reset function on the output side. On one hand, within the stable twisted pair zone 121, adjacent twisted pair units 130 in opposite directions need to maintain a misaligned fit to reduce the risk of local congestion, width fluctuation, or local bulging after thermal pressing caused by the close proximity of the wire cores 10 at adjacent boundaries. On the other hand, on the output side of the local twisted pair section 120, multiple wire cores 10 need to enter the subsequent straight section 112 and restore the target wire sequence and target pitch in the subsequent straight section 112 to meet the subsequent termination requirements. If the twisted phase of the entire local twisted segment 120 is directly adjusted to meet the target wiring sequence of the subsequent straight segment 112, it is easy to disrupt the misalignment relationship between adjacent twisted units 130 within the stable twisted area 121. If only the misaligned twisted relationship within the stable twisted area 121 is guaranteed, the pairing group 11 may not be able to stably restore to the target wiring sequence after twisting. Therefore, in this embodiment, the stable twisted area 121 mainly undertakes the boundary clearance function, and the phase recovery area 122 mainly undertakes the phase transition and closure reset functions before twisting.

[0035] In S20, a boundary clearance constraint is generated based on the adjacent boundary 140 between two adjacent twisted units 130, and a closed reset constraint is generated based on the target line sequence of the subsequent straight segments 112.

[0036] Specifically, an adjacent boundary 140 is formed between two adjacent twisted pairs 130 along the width direction W. The adjacent boundary 140 is the dividing area between two adjacent twisted pairs 130. Each adjacent boundary 140 has a boundary side core 12 on both sides, and the boundary side core 12 is a core 10 of the corresponding twisted pair 130 that is closer to the adjacent boundary 140. Within the stable twisted pair area 121, the boundary side core 12 moves closer to or further away from the adjacent boundary 140 in the width direction W as the corresponding twisted pairs 130 are periodically twisted. If the boundary side cores 12 on both sides of the same adjacent boundary 140 are close to the adjacent boundary 140 at the same length position, local congestion is likely to occur at the adjacent boundary 140. This local congestion may manifest as local width fluctuations before hot pressing, and may manifest as local bulges, local compression, or uneven twisted appearance after hot pressing.

[0037] When generating boundary clearance constraints, first determine the adjacent boundary 140 between two adjacent twisted pairs 130 along the width direction W, and then determine the boundary side cores 12 on both sides of the adjacent boundary 140. Then, determine the preset clearance distance D according to the target twist pitch P, and write "the length direction positions of the boundary side cores 12 on both sides of the same adjacent boundary 140 reaching the local minimum distance from the adjacent boundary 140 are staggered by no less than the preset clearance distance D" as a boundary clearance constraint into the processing recipe. In this way, when the boundary side core 12 in one twisted pair 130 is close to the adjacent boundary 140 at a certain length position, the boundary side core 12 in another adjacent twisted pair 130 is not close to the adjacent boundary 140 at the same length position, but is staggered by a certain distance in the length direction L, thus forming a staggered clearance relationship.

[0038] In some embodiments, the preset clearance distance D is determined based on the target twist pitch P of the twisted unit 130. The target twist pitch P is the length corresponding to one twisting cross cycle formed by the twisted unit 130 along the length direction L. The preset clearance distance D can be 1 / 4 to 3 / 4 of the target twist pitch P, preferably close to 1 / 2 of the target twist pitch P. Within the stable twisted region 121, two adjacent twisted units 130 form a staggered twisted structure with a continuous twisting cross cycle of no less than two twisting cross cycles according to the preset clearance distance D, so that the boundary clearance relationship exists continuously within the stable twisted region 121, rather than being accidentally staggered at a single position.

[0039] Boundary clearance constraints can be determined during the processing recipe design stage based on the target twist pitch P and the preset twist direction. Alternatively, they can be determined after trial processing by manually observing, acquiring images, and checking templates or rulers to see if the boundary side cores 12 at adjacent boundaries 140 are in close proximity or have local width fluctuations. If the trial-processed part shows local congestion or width fluctuations at adjacent boundaries 140, the boundary clearance constraints can be satisfied within the stable twisted pair area 121 by adjusting the preset clearance distance D, the target twist pitch P of the stable twisted pair area 121, or the initial phase relationship between adjacent twisted pair units 130.

[0040] When generating the closed reset constraint, the reset requirements after twisting are determined based on the target wire sequence and target pitch allowable range of the subsequent straight section 112. The target wire sequence is the target arrangement order of multiple wire cores 10 along the width direction W in the subsequent straight section 112. This target wire sequence can be consistent with the wire core arrangement order in the preceding straight section 111, or it can be preset in the processing formula according to termination requirements, connector hole positions, or customer product specifications. The closed reset constraint includes: after twisting, the two wire cores 10 in each pairing group 11 are restored to the corresponding width direction order in the target wire sequence, and the center distance between adjacent wire cores 10 in the subsequent straight section 112 is within the target pitch allowable range. Through this closed reset constraint, it is possible to avoid wire sequence misalignment, excessive pitch, excessive pitch, or local bending and stacking in the subsequent straight section 112 even though the wire cores 10 have exited the twisted state.

[0041] Therefore, the boundary yielding constraint and the closed reset constraint output by S20 correspond to the stable twisting requirement inside the local twisted segment 120 and the line sequence reset requirement of the subsequent straight segment 112, respectively. Together, they serve as the constraint conditions for determining the phase recovery zone parameters.

[0042] In S30, while maintaining the stable twisted pair 121 and satisfying the boundary yield constraint, the phase recovery zone parameters are determined based on the closed reset constraint.

[0043] Specifically, when determining the phase recovery zone parameters, the processing formula prioritizes ensuring that the stable twisted zone 121 meets the boundary clearance constraints, rather than directly perturbing the twisted phase of the entire stable twisted zone 121 to meet the reset requirements of the subsequent straight section 112. In other words, the stable twisted zone 121 prioritizes maintaining the misalignment and clearance relationship between the target twist pitch P, the preset twist direction, and adjacent twisted units 130; when the exit phase of the stable twisted zone 121 on the exit side is inconsistent with the reset phase required by the subsequent straight section 112, the phase difference between the two is processed in the phase recovery zone 122.

[0044] In this embodiment, the phase change corresponding to a complete twisted crossover cycle is defined as 360°, and the exit phase, reset phase, and phase difference to be recovered are all determined based on this phase reference. The twisted phase is determined by the position of the pairing group 11 in the length direction L, the rotation angle of the twisting actuator, the target twist pitch P, and the traction length. The exit phase is the twisted phase state of the pairing group 11 at the end of the stable twisted zone 121; the reset phase is the twisted phase state required for the two wire cores 10 to return to the target wire sequence and target pitch of the subsequent straight section 112 after the pairing group 11 exits the twist at the exit end; the phase difference to be recovered is the difference between the exit phase and the reset phase that exceeds the preset phase allowable range. The preset phase allowable range can be preset according to the target pitch allowable range of the subsequent straight section 112, the diameter of the wire core 10, the termination position accuracy, and the positioning accuracy of the processing equipment.

[0045] When determining the phase recovery zone parameters based on the closed reset constraint, firstly, based on the target pitch P of the stable twisted pair 121, the length of the stable twisted pair 121, and the preset twist direction of each pairing group 11, the exit phase of the pairing group 11 reaching the exit side of the stable twisted pair 121 when the boundary clearance constraint is satisfied is determined; then, the reset phase is determined based on the closed reset constraint; subsequently, the exit phase and the reset phase are compared, and if the difference between the two exceeds the preset phase allowable range, the difference is determined as the phase difference to be recovered. The phase recovery zone parameters include at least the length of the phase recovery zone 122, the number of recovery segments 123, the segment length of each recovery segment 123, the local target pitch of each recovery segment 123, and the unit phase adjustment amount corresponding to each recovery segment 123.

[0046] To reduce the phase difference that the phase recovery zone 122 needs to process, the length of the stable twisted pair 121 can be adjusted within the allowable length of the stable twisted pair as preset in the processing formula, according to one twisting cycle, half a twisting cycle, or a preset cycle unit. This makes the adjusted exit phase close to the reset phase, and the remaining phase difference after adjustment is taken as the remaining phase difference to be recovered. The allowable length of the stable twisted pair can be determined based on the target length of the local twisted segment 120, the termination position requirements, and the allowable fluctuation range of the effective twisted length. This step is equivalent to first performing a periodic coarse adjustment using the length of the stable twisted pair 121, and then having the phase recovery zone 122 handle the fine adjustment of the remaining phase difference, thereby avoiding the phase recovery zone 122 bearing an excessive amount of phase adjustment within a short length. When the product specifications do not allow adjustment of the length of the stable twisted pair 121, or when adjusting the length of the stable twisted pair 121 would affect the target length of the local twisted segment 120, the length adjustment of the stable twisted pair 121 can be omitted, and the phase difference to be recovered can be directly allocated to one or more recovery sub-segments 123 within the phase recovery zone 122.

[0047] The phase recovery zone 122 is divided into multiple recovery segments 123 along its length L. Each recovery segment 123 corresponds to a segment length, a local target pitch, and a unit phase adjustment amount in the processing formula. Along the direction from the stable twisting zone 121 to the subsequent straight section 112, the unit phase adjustment amounts corresponding to the multiple recovery segments 123 are sequentially applied to at least a portion of the paired groups 11, causing the twisting phase of at least a portion of the paired groups 11 to gradually approach the reset phase, and ensuring that the sum of the unit phase adjustment amounts of the multiple recovery segments 123 corresponds to the remaining phase difference to be recovered. Thus, the phase recovery zone 122 is not a simple morphological transition section, but a phase processing section segmented according to the phase difference to be recovered, with local target pitch or unit phase adjustment amounts configured in segments.

[0048] For any recovery segment 123, when the segment length of the recovery segment 123 is Li and the corresponding local target pitch is Pi, where i represents the sequence number of the recovery segment 123, the amount of twisted phase change formed within the recovery segment 123 is determined according to the ratio of Li to Pi. By changing the local target pitch Pi, the amount of the recovery segment 123 that shares the remaining phase difference to be recovered can be changed. For example, when the length of the recovery segment 123 is fixed, decreasing the local target pitch Pi can increase the amount of twisted phase change formed within the recovery segment 123; increasing the local target pitch Pi can decrease the amount of twisted phase change formed within the recovery segment 123. Thus, multiple recovery segments 123 can share the remaining phase difference to be recovered through different local target pitches Pi, so that the pairing group 11 gradually approaches the phase state that satisfies the closed reset constraint before reaching the exit twist end.

[0049] If the twisted phase of the entire local twisted segment 120 is set only according to the boundary clearance constraint, the adjacent twisted units 130 in the stable twisted area 121 can maintain a good misalignment relationship. However, some pairing groups 11 may not reach the reset phase at the exit twist end, which may easily cause line sequence sway or pitch deviation after entering the subsequent straight section 112. If the twisted phase of the entire local twisted segment 120 is directly adjusted in order to meet the target line sequence of the subsequent straight section 112, it may destroy the boundary clearance relationship originally formed in the stable twisted area 121, causing the boundary side cores 12 on both sides of the adjacent boundary 140 to simultaneously approach the adjacent boundary 140 at the local length position, resulting in local congestion or width fluctuation. Therefore, this embodiment sets the stable twisted area 121 and the phase recovery area 122 separately, so that the pairing group 11 gradually approaches the reset phase in the phase recovery area 122 without destroying the boundary clearance relationship of the stable twisted area 121.

[0050] In S40, the twisting actuator is controlled according to the preset twisting direction to perform partial twisting processing on the multiple continuously transmitted wire cores 10, and the traction actuator and / or twisting actuator are controlled according to the phase recovery zone parameters to make the pairing group 11 complete the twisting phase recovery in the phase recovery zone 122, and then the multiple wire cores 10 are hot-pressed and shaped.

[0051] Specifically, within the stable twisted pair zone 121, the traction actuator continuously pulls multiple wire cores 10 to move along the length direction L. The twisting actuator performs twisting actions on multiple paired groups 11 according to the preset twisting direction corresponding to each paired group 11, so that multiple paired groups 11 form continuous twisted units 130 within the stable twisted pair zone 121, and adjacent twisted units 130 satisfy the boundary clearance constraint. At this time, the stable twisted pair zone 121 mainly maintains the misalignment and clearance relationship between the target twist pitch P and adjacent twisted units 130.

[0052] Within the phase recovery zone 122, the traction actuator and / or the twisting actuator change the local twisting processing state according to the phase recovery zone parameters. When the wire core 10 enters any recovery segment 123, the traction actuator pulls the wire core 10 according to the segment length corresponding to that recovery segment 123, and the twisting actuator adjusts the twisting angular velocity or the number of twisting rotations according to the local target twist pitch corresponding to that recovery segment 123, so that the unit length twisting phase change within that recovery segment 123 corresponds to the unit phase adjustment amount. After multiple recovery segments 123 complete phase adjustment sequentially, the twisting phase of the paired group 11 gradually approaches or reaches the reset phase.

[0053] In one processing method, the angular velocity of the twisting actuator remains constant, while the traction actuator changes the amount of twist phase change per unit length by altering the traction speed. In another processing method, the traction speed of the traction actuator remains constant, while the twisting actuator changes the amount of twist phase change per unit length by altering the twist angular velocity or the number of twist rotations. In yet another processing method, the traction actuator and the twisting actuator are adjusted simultaneously to ensure that the local target twist pitch within the recovery segment 123 meets the processing formula requirements. Therefore, the phase recovery in this embodiment does not require the equipment to have an additional independent phase adjustment mechanism, but can be achieved through speed coordination between the twisting actuator and the traction actuator, length position control, or twist exit control position setting.

[0054] After the pairing group 11 passes through the phase recovery zone 122, the guiding mechanism guides multiple wire cores 10 into the subsequent straight section 112, causing the wire cores 10 to transition from a partially twisted state to a parallel straight state. A spacing mechanism limits the width spacing between adjacent wire cores 10, ensuring that the multiple wire cores 10 maintain the target wire sequence and target pitch within the subsequent straight section 112. Subsequently, a hot-pressing mechanism performs hot-pressing shaping on the multiple wire cores 10. Hot-pressing shaping can be applied to at least a portion of the stable twisted zone 121, the phase recovery zone 122, and the subsequent straight section 112. Hot-pressing shaping is used to fix the misaligned twisted state formed in the stable twisted zone 121, the phase transition state formed in the phase recovery zone 122, and the target wire sequence and target pitch formed in the subsequent straight section 112, thereby reducing deformation of the partially twisted section 120 or pitch changes in the subsequent straight section 112 caused by the springback of the wire cores 10 during subsequent handling, termination, or assembly.

[0055] To further illustrate the processing logic of this embodiment, in a set of processing formulas, the target twist pitch P of the local twisted pair cable 100 is 24mm, the target length of the stable twisted pair zone 121 is 192mm, and 8 twisting cycles are formed within the stable twisted pair zone 121. The preset clearance distance D is set to P / 2, i.e., 12mm, so that the boundary side cores 12 of two adjacent twisted pair units 130 are staggered along the length direction L by about half a twist pitch near the adjacent boundary 140. If the exit phase calculated based on the target twist pitch P and the length of the stable twisted pair zone 121 has a 90° phase difference with the reset phase required by the subsequent straight section 112, then a phase recovery zone 122 is set up, and the phase recovery zone 122 is divided into three recovery sub-segments 123. Each recovery sub-segment 123 undertakes a unit phase adjustment of about 30°. During processing, the twisting actuator and the traction actuator execute segment by segment according to the local target twist pitch and segment length corresponding to each recovery segment 123, so that the twisted phase of the pairing group 11 gradually approaches the reset phase. After passing through the phase recovery zone 122, multiple wire cores 10 enter the subsequent straight section 112 through the guiding mechanism and the spacing maintenance mechanism, and are hot-pressed and shaped under the action of the hot-pressing mechanism. The above values ​​are only used to illustrate the process of determining the phase recovery zone parameters and do not limit the specific values ​​of the target twist pitch P, the length of the stable twisted zone 121, the phase difference, or the number of recovery segments 123.

[0056] Through the above implementation, this application can maintain the misalignment and clearance state of adjacent reverse twisted pair units 130 within the stable twisted pair zone 121, while gradually absorbing the phase difference between the exit phase and the reset phase within the phase recovery zone 122, so that multiple wire cores 10 can restore the target wire sequence and target pitch after entering the subsequent straight section 112. Therefore, the risk of local congestion or width fluctuations in adjacent twisted pair units 130 at adjacent boundaries 140 can be reduced, and the forming consistency of the local twisted pair section 120 and the subsequent straight section 112 during continuous batch processing can be improved.

[0057] In the above embodiments, the stable twisted pair zone 121, the phase recovery zone 122, and the recovery segment 123 can all be determined by the length position, segment length, and local target twist pitch in the processing formula. The twisting actuator, traction actuator, guiding mechanism, spacing maintenance mechanism, and hot pressing mechanism can be replaced according to different equipment forms. As long as multiple wire cores 10 can form a local twisted structure during continuous transmission, and a stable wiring structure is formed after local twisting through guiding, spacing maintenance, and hot pressing, the technical solution of this application can be realized.

[0058] The embodiments described above are merely examples of several implementations of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these modifications and improvements all fall within the scope of protection of this application.

Claims

1. A method for continuous batch processing of partially twisted ribbon cables, wherein the ribbon cable comprises multiple cores arranged side-by-side along its width, two adjacent cores forming a pairing group, the ribbon cable having a partially twisted section along its length and a subsequent straight section located on the out-of-twist side of the partially twisted section, two adjacent pairing groups being respectively used to form twisted units with opposite twisting directions within the partially twisted section, characterized in that, include: S10. Determine the corresponding preset twisting direction according to the arrangement order of each pairing group, and determine a stable twisting area and a phase recovery area located on the outgoing side of the stable twisting area within the local twisting segment; wherein, the stable twisting area is used to enable multiple pairing groups to form a continuous twisting unit with the corresponding preset twisting direction. S20. Generate boundary clearance constraints based on the adjacent boundaries between two adjacent twisted units, and generate closed reset constraints based on the target line sequence of the subsequent straight segments. S30. While ensuring that the stable twisted pair satisfies the boundary yielding constraint, determine the phase recovery zone parameters according to the closed reset constraint; S40. According to the preset twisting direction control, the twisting actuator performs partial twisting processing on the multiple continuously transmitted wire cores, and controls the traction actuator and / or the twisting actuator according to the phase recovery zone parameters, so that the pairing group completes the twisting phase recovery in the phase recovery zone, and then performs hot pressing and shaping on the multiple wire cores.

2. The method of claim 1, wherein, The local twisted section includes, along its length, the stable twisted region and the phase recovery region, with the phase recovery region located between the stable twisted region and the subsequent straight section. The stable twisting zone is used to enable multiple pairing groups to form a continuous twisting structure with a target twisting pitch according to the corresponding preset twisting direction, and the phase recovery zone is used to enable at least some of the pairing groups to transition from a twisting phase that satisfies the boundary yielding constraint to a twisting phase that satisfies the closed reset constraint.

3. The method of claim 1, wherein, The adjacent boundary is located between two adjacent twisted pairs along the width direction, and each side of the adjacent boundary has a boundary side wire core, which is a wire core in the twisted pair that is closer to the adjacent boundary. The boundary clearance constraint includes: the length direction positions of the boundary side line cores on both sides of the same adjacent boundary reach the local minimum distance from the adjacent boundary, and are offset along the length direction of the wiring by a distance not less than a preset clearance distance.

4. The method of claim 3, wherein, The preset clearance distance is determined based on the target twist pitch of the twisted unit within the stable twisted zone, and the preset clearance distance is 1 / 4 to 3 / 4 of the target twist pitch. Within the stable twisted zone, two adjacent twisted units form a staggered twisted structure with a continuous twisting cross cycle of no less than two twisting cycles according to the preset clearance distance.

5. The method of claim 1, wherein, The target line sequence is the target arrangement order of the multiple core wires along the width direction in the subsequent straight section; The closed reset constraint includes: after each pairing group is twisted out, the two cores in each pairing group are restored to the width direction sequence corresponding to the target line sequence, and the center distance between adjacent cores in the subsequent straight section is within the allowable range of the target pitch.

6. The method of claim 5, wherein, Determining the phase recovery zone parameters based on the closed reset constraint includes: determining the exit phase of the pairing group when it reaches the exit side of the stable twisted zone, based on the preset target twist pitch of the stable twisted zone, the preset length of the stable twisted zone, and the preset twist direction of each pairing group; The phase exiting the zone is compared with the reset phase corresponding to the closed reset constraint, and when the difference between the two exceeds the preset phase allowable range, the difference is determined as the phase difference to be recovered.

7. The method of claim 6, wherein, Before determining the phase recovery zone parameters, within the preset allowable length of the stable twisted zone, the length of the stable twisted zone is adjusted according to one twisted cycle, half a twisted cycle, or a preset cycle unit corresponding to the target twist pitch of the stable twisted zone, so that the adjusted exit phase is close to the reset phase, and the remaining phase difference after adjustment is taken as the remaining phase difference to be recovered.

8. The method of claim 7, wherein, The phase recovery zone is divided into multiple recovery segments along the length direction. Each recovery segment corresponds to a segment length, a local target pitch, and a unit phase adjustment amount in the processing formula. Along the direction from the stable twisted pair area to the subsequent straight section, the unit phase adjustment amount corresponding to the plurality of the recovery sub-segments is sequentially applied to at least a portion of the pairing groups, so that the twisted phase of the at least a portion of the pairing groups gradually approaches the reset phase, and the sum of the unit phase adjustment amounts of the plurality of recovery sub-segments corresponds to the remaining phase difference to be recovered.

9. The method of claim 8, wherein, During partial twisting processing, the twisting actuator performs twisting action on multiple paired groups according to the preset twisting direction; When the wire core enters any of the recovery segments, the traction actuator pulls the wire core according to the segment length corresponding to the recovery segment, and the twisting actuator adjusts the twisting angular velocity or the number of twisting rotations according to the local target twisting pitch corresponding to the recovery segment, so that the unit length twisting phase change within the recovery segment corresponds to the unit phase adjustment amount.

10. The method for continuous batch processing of partially twisted busbars according to claim 9, characterized in that, After the pairing group passes through the phase recovery zone, the multiple cores are guided into the subsequent straight section by the guiding mechanism, and the spacing between adjacent cores is limited by the spacing keeping mechanism, so that the multiple cores maintain the target line sequence and target pitch in the subsequent straight section; After the guiding mechanism and / or the spacing mechanism, the multiple core wires are hot-pressed and shaped by the hot pressing mechanism so that the wiring remains in a straight parallel state in the subsequent straight section and the local twisted section remains in a shaped state where the adjacent twisted units have opposite twisting directions.

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