A closed-loop industrial automatic control method for pressure displacement during insulator crimping process

Abstract

This invention discloses a closed-loop industrial automatic control method for pressure displacement in the insulator crimping process, specifically relating to the field of industrial automatic control technology. The method includes acquiring the target effective crimping displacement issued by the centralized manufacturing control terminal according to the insulator crimping process number; the edge IoT acquisition terminal synchronously reads the analog pressure quantity and the analog cylinder displacement quantity within the scanning cycle of the programmable logic controller (PLC), and generates a pressure displacement scanning chain through analog-to-digital conversion; the intelligent sensing system performs sensor consistency processing on the pressure displacement scanning chain, binding pressure scan words and displacement scan words according to the same scanning cycle; by synchronously forming the pressure displacement scanning chain within the PLC scanning cycle, after locating the crimping change point, short-range pressure release and in-situ re-pressurization are sequentially executed to separate the equipment rebound displacement and the fitting gap displacement; and after obtaining the effective crimping displacement estimate using volumetric Kalman filtering, the crimping action output state is rewritten.

Description

Technical Field

[0001] This invention relates to the field of industrial automatic control technology, and more specifically, to a closed-loop industrial automatic control method for pressure displacement during insulator crimping. Background Technology

[0002] Insulator crimping equipment typically uses a PLC to collect signals from pressure and displacement sensors, and controls the hydraulic cylinder to operate according to the set pressure, set displacement, holding time, or pressure-displacement curve range to avoid insufficient crimping and overpressure damage. In the continuous crimping production of composite insulator end fittings, the workpiece is in the mold clamping state and cannot be removed for inspection during the crimping process. The controller needs to complete the judgment of pressurization, pressure holding and shutdown within one crimping stroke. The data that can be obtained in real time on site are mainly the pressure value, the cylinder displacement value and the response change during the pressure relief return stroke. Since the displacement sensor records the total displacement formed by the cylinder propulsion, the total displacement is mixed with displacement from different sources such as mold elastic compression, assembly gap elimination, fitting slippage and fitting plastic clamping. Even if the pressure-displacement curve falls within the qualified range, there may still be different rebound amounts and different residual clamping amounts after pressure is released, which may cause inconsistencies in end dimensions, pull-out force or clamping holding force of the same batch of workpieces. The technical problem to be solved by this application is: how to separate the elastic deformation and the contact gap from the total displacement of the hydraulic cylinder during the insulator crimping process, determine the effective crimping displacement that actually acts on the workpiece, and control the crimping action accordingly. Summary of the Invention

[0003] To overcome the aforementioned deficiencies in the prior art, embodiments of the present invention provide a closed-loop industrial automatic control method for pressure displacement in the insulator crimping process. By synchronously forming a pressure displacement scanning chain within the PLC scanning cycle, short-range pressure release and in-situ re-pressure are sequentially executed after locating the crimping change point, separating the equipment rebound displacement from the bonding gap displacement, and rewriting the crimping action output state after obtaining the effective crimping displacement estimate using volumetric Kalman filtering, thereby solving the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a closed-loop industrial automatic control method for pressure displacement during insulator crimping, comprising: S1. Obtain the target effective crimping displacement issued by the centralized manufacturing control terminal according to the insulator crimping process number. The edge IoT acquisition terminal synchronously reads the pressure analog quantity and the cylinder displacement analog quantity within the scanning cycle of the programmable logic controller, and generates a pressure displacement scanning chain through analog-to-digital conversion. S2. Perform sensor consistency sorting on the pressure-displacement scanning chain through the intelligent sensing system, bind pressure scanning words and displacement scanning words according to the same scanning cycle, and generate a pressing response slope chain by dividing the pressure difference between adjacent scanning cycles by the displacement difference; execute the wild binary change point detection algorithm on the pressing response slope chain, generate scanning segments according to the combination of scanning positions, scan candidate segment positions one by one and calculate the absolute value of the difference between the mean values ​​of the left and right slopes, and write the candidate segment position ranked first as the pressing change point; S3. During the scanning cycle corresponding to the point of change in pressing, output the short-range pressure relief control word according to the ladder diagram logic. The hydraulic valve group reduces the cylinder pressure and maintains the mold clamping. The edge IoT acquisition terminal reads the reverse change of the displacement scanning word and generates the equipment springback displacement word. S4. After the short-range pressure relief ends, the in-situ pressure control word is output according to the functional diagram step relationship. The hydraulic valve group resumes pressurization. The edge IoT acquisition terminal reads the advance amount of the displacement scan word before the pressure scan word is incremented again and generates the fitting gap displacement word. S5. Execute the volumetric Kalman filter algorithm based on the displacement scanning word, equipment springback displacement word, and bonding gap displacement word corresponding to the crimping change point. Generate bidirectional volume points with three-component displacement state words. Generate effective crimping displacement estimation word through state propagation and arithmetic mean operation. Rewrite the crimping action output state according to the sign of the difference between the effective crimping displacement estimation word and the target effective crimping displacement, and send it back to the centralized manufacturing control terminal.

[0005] In a preferred embodiment, S1 includes: S11. The centralized manufacturing control terminal writes the insulator crimping process number as an unsigned integer into the process register. The programmable logic controller uses the process register value as the row address of the target displacement table, reads the target effective crimping displacement recorded in micrometers, removes the target effective crimping bit, counts the displacement by the hydraulic cylinder displacement sensor, takes the integer quotient when the remainder is zero, and takes the integer quotient plus one when the remainder is non-zero, and generates the target effective crimping displacement meter number. S12. At the beginning edge of the scan cycle, increment the scan cycle counter to generate the current scan cycle number. Simultaneously write the current scan cycle number to the pressure sampling latch and the displacement sampling latch. The pressure and displacement intelligent sensing system maintains the pressure analog quantity and the cylinder displacement analog quantity on the same latch edge, and generates the pressure gauge digital and displacement gauge digital respectively through analog-to-digital conversion. S13. Using the current scan cycle number as the scan slot address, write the pressure gauge number into the pressure field, the displacement gauge number into the displacement field, and the target effective pressing displacement gauge number into the target field. Then, read each scan slot in ascending order of the scan slot address to generate a pressure-displacement scan chain consisting of the scan slot address, pressure field, displacement field, and target field.

[0006] In a preferred embodiment, S2 includes: S21. The pressure displacement intelligent sensing system reads the pressure displacement scanning chain, reads the pressure field and displacement field according to the scanning slot address, writes zero to the crimping response slope word of the starting scanning slot address, subtracts the previous pressure field from the current pressure field to obtain the pressure difference value for the next scanning slot address, and subtracts the previous displacement field from the current displacement field to obtain the displacement difference value. When the displacement difference is zero, the previous crimping response slope word is used. When the displacement difference is non-zero, the current crimping response slope word is generated by dividing the pressure difference value by the displacement difference value. The crimping response slope chain is generated in ascending order of the scanning slot address. S22. The pressure displacement intelligent sensing system performs a wild binary change point detection algorithm on the crimp response slope chain. Using the chain length of the crimp response slope chain as the remainder base, the wild left end is generated by adding the square of the scan slot address to the scan slot address and taking the remainder. The wild right end is generated by adding twice the scan slot address to the square of the scan slot address and taking the remainder. The scan bit combination where the wild left end is less than the wild right end is written into the wild scan sub-segment table. The scan bit combination where the wild left end is greater than the wild right end is swapped and written into the wild scan sub-segment table.

[0007] In a preferred embodiment, S2 further includes: S23. For each scan segment in the wild scan segment table, scan the candidate segmentation position between the left end and the right end of the scan segment one by one. Calculate the arithmetic mean of the pressure response slope words from the left end of the scan segment to the candidate segmentation position to obtain the left slope mean. Calculate the arithmetic mean of the pressure response slope words from the next candidate segmentation position to the right end of the scan segment to obtain the right slope mean. Write the absolute value of the difference between the left slope mean and the right slope mean as the segmentation cost. S24. Arrange the candidate segmentation bits in descending order of segmentation value and ascending order of candidate segmentation bits. Read the first candidate segmentation bit in the sorted order as the crimping change point and write the scan slot address corresponding to the crimping change point into the change point register of the programmable logic controller.

[0008] In a preferred embodiment, S3 includes: S31. Read the scanning slot address corresponding to the pressure change point, write the displacement field of the corresponding scanning slot address as the pressure relief start point displacement meter number, and write the integer obtained by subtracting the pressure field of the next scanning slot address from the pressure field of the previous scanning slot address as the pressure relief differential meter number. S32. Divide the pressure field of the previous scan slot address by the pressure differential pressure gauge number. If the remainder is zero, take the integer quotient as the pressure differential pressure gauge number. If the remainder is not zero, take the integer quotient plus one as the pressure differential pressure gauge number. Write the pressure differential pressure gauge number into the pressure differential pressure counter of the ladder diagram.

[0009] In a preferred embodiment, S3 further includes: S33. The pressure relief counter decrements by one after each scan cycle. During the period when the pressure relief counter is not zero, the ladder diagram outputs a short-range pressure relief control word with the clamping coil potential at one, the pressurizing coil potential at zero, and the pressure relief coil potential at one, so that the hydraulic valve group shuts off the pressurizing oil circuit, connects the pressure relief oil circuit, and keeps the clamping oil circuit open. S34. During the period when the pressure relief counter is not zero, the edge IoT acquisition terminal reads the displacement field of each scanning cycle, subtracts the displacement field of the current cycle from the displacement meter number at the pressure relief start point to generate the displacement meter number of the current cycle, and accumulates the positive integers in the displacement meter number of the current cycle to generate the device rebound displacement word.

[0010] In a preferred embodiment, S4 includes: S41. During the scan cycle when the pressure relief counter returns to zero, read the displacement field of the corresponding scan slot address and write it as the displacement value of the pressure recovery start point. At the same time, write the pressure relief step bit to zero and the pressure recovery step bit to one in the function chart step register. S42. When the repressurization step is one, the function diagram outputs an in-situ repressurization control word with the pressure relief coil potential at zero, the pressure increase coil potential at one, and the clamping coil potential at one, so that the hydraulic valve group shuts off the pressure relief oil circuit, connects the pressure increase oil circuit, and keeps the clamping oil circuit open.

[0011] In a preferred embodiment, S4 further includes: S43. In each scanning cycle with a re-pressure step of one, the edge IoT acquisition terminal reads the pressure field of the current scanning slot address and the pressure field of the previous scanning slot address, and subtracts the two to generate the pressure increment word of the current cycle. When the pressure increment word of the current cycle is zero or a negative integer, it continues to be written to the next scanning slot. When the pressure increment word of the current cycle is a positive integer, the previous scanning slot address is written as the gap end scanning slot address, and the re-pressure step is written to zero. S44. Read the displacement field of the gap end scan slot address, and subtract the displacement meter number of the overpressure start point from the displacement field of the gap end scan slot address to generate the fitting gap displacement word.

[0012] In a preferred embodiment, S5 includes: S51. Read the displacement field, equipment springback displacement word, and bonding gap displacement word of the scanning slot address corresponding to the crimping change point. Subtract the equipment springback displacement word from the displacement field and then subtract the bonding gap displacement word to generate the initial effective crimping displacement word. When the calculation result is a negative integer, write the initial effective crimping displacement word to zero. The initial effective crimping displacement word, equipment springback displacement word, and bonding gap displacement word form a three-component displacement status word. S52. According to the capacitive Kalman filter algorithm, multiply the digit of each component in the three-component displacement state word by three and take the square root. When the remainder is zero, take the square root of the integer. When the remainder is non-zero, take the square root of the integer plus one to generate three capacitive radius words. Then, perform the addition and subtraction of the capacitive radius word on the corresponding component respectively. Write zero for the negative integer operation result to generate six bidirectional capacitive points. S53. Read the springback component and gap component for each bidirectional volume point. Subtract the springback component and then the gap component from the displacement field of the scanning slot address corresponding to the crimping change point to generate the propagation effective component. Write the negative integer calculation result as zero. The propagation volume point is composed of the propagation effective component, springback component and gap component.

[0013] In a preferred embodiment, S5 further includes: S54. Add the effective propagation components of the six propagation volume points and divide by six. If the remainder is zero, take the integer quotient. If the remainder is not zero, take the integer quotient and add one to generate the intermediate effective pressing displacement word. Then, subtract the equipment springback displacement word, the bonding gap displacement word, and the intermediate effective pressing displacement word from the displacement field to generate the closed residual word. Finally, add the intermediate effective pressing displacement word and the closed residual word to generate the effective pressing displacement estimation word. S55. Subtract the target effective crimp displacement meter number from the effective crimp displacement estimation word to generate the target difference word. When the target difference word is a negative integer, write the pressurization output bit as 1. When the target difference word is zero, write the hold output bit as 1. When the target difference word is a positive integer, write the depressurization output bit as 1. Write the effective crimp displacement estimation word and the output bit to the centralized manufacturing control terminal using the insulator crimping process number as the record address.

[0014] The technical effects and advantages of this invention are as follows: 1. This solution obtains the equipment springback displacement value through short-range pressure relief and the fitting gap displacement value through in-situ re-pressure. The non-workpiece deformation amount in the total displacement of the hydraulic cylinder is deducted, thereby relatively accurately determining the effective pressing displacement acting on the workpiece. 2. After binding the pressure field and displacement field with the same scan cycle, a pressure response slope chain is generated, so that pressure changes and displacement changes participate in the judgment with the same time base, reducing the shift of change points caused by asynchronous sampling; 3. Perform wild binary change point detection on the crimping response slope chain to locate the crimping change point corresponding to the sudden change in crimping state, so that the pressure release action is triggered by process data, thereby reducing the judgment deviation caused by fixed set values. 4. After the crimping change point, the ladder diagram outputs a short-range pressure relief control word and the function diagram outputs an in-situ pressure restoration control word, so that the hydraulic valve group action corresponds to the PLC scanning cycle, which facilitates the execution of control within one crimping stroke; 5. The effective displacement, rebound displacement and gap displacement are used to form a three-component displacement state word, and volumetric Kalman propagation and residual correction are performed to make the effective pressing displacement estimation relatively suppress the influence of single sampling fluctuations. 6. Write the effective crimping displacement estimation word and output bit back to the centralized manufacturing control terminal according to the process number, so that multiple crimping devices can perform judgment based on the same counting field, which can improve the consistency of continuous production. Attached Figure Description

[0015] Figure 1 This is a flowchart outlining the method steps of the present invention. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Refer to the instruction manual appendix Figure 1 The present invention provides a closed-loop industrial automatic control method for pressure displacement during insulator crimping, comprising: S1. Obtain the target effective crimping displacement issued by the centralized manufacturing control terminal according to the insulator crimping process number. The edge IoT acquisition terminal synchronously reads the pressure analog quantity and the cylinder displacement analog quantity within the scanning cycle of the programmable logic controller, and generates a pressure displacement scanning chain through analog-to-digital conversion. This implementation method is used to write the crimping target, pressure sampling result, and cylinder displacement sampling result issued by the centralized manufacturing control terminal into the same scanning slot, so that subsequent S2 can directly read adjacent pressure fields and adjacent displacement fields according to the scanning slot address; the pressure and displacement intelligent sensing system consists of an edge IoT acquisition terminal, a pressure sampling latch terminal, a displacement sampling latch terminal, a pressure analog-to-digital converter, and a displacement analog-to-digital converter; the edge IoT acquisition terminal is responsible for sending the converted pressure gauge digital and displacement gauge digital into the scanning slot, and the pressure and displacement intelligent sensing system is responsible for synchronous holding and analog-to-digital conversion on the same latch edge; this implementation method includes the following steps: In S11, the centralized manufacturing control terminal writes the insulator crimping process number as an unsigned integer into the process register; the programmable logic controller reads the process register value and uses the process register value as the row address of the target displacement table to read the target effective crimping displacement recorded in the target displacement table in micrometers. The single-count displacement of the hydraulic cylinder displacement sensor is read from the calibration record of the hydraulic cylinder displacement sensor, and the unit is micrometer. The target effective pressing position is removed by the single-count displacement of the hydraulic cylinder displacement sensor. When the remainder is zero, the integer quotient is written as the target effective pressing displacement meter number. When the remainder is not zero, the integer quotient is incremented by one and written as the target effective pressing displacement meter number. When the process register value does not have a corresponding row in the target displacement table, the target effective pressing displacement meter value is written to zero, and the target field is written with the target missing flag; when the single count displacement of the hydraulic cylinder displacement sensor is zero, the target effective pressing displacement meter value is written to zero, and the target field is written with the displacement calibration missing flag; when subsequent steps read the target missing flag or the displacement calibration missing flag, no pressurization action is output. In S12, when the start edge of the scan cycle arrives, the scan cycle counter is incremented by one to generate the current scan cycle number; the current scan cycle number is simultaneously written to the pressure sampling latch and the displacement sampling latch. The pressure-displacement intelligent sensing system holds the analog pressure and the analog cylinder displacement on the same latching edge. The analog pressure is converted into a pressure gauge digital value by a pressure analog-to-digital converter, and the analog cylinder displacement is converted into a displacement gauge digital value by a displacement analog-to-digital converter. The pressure gauge reading is an integer output from the pressure analog-to-digital converter, and the displacement gauge reading is an integer output from the displacement analog-to-digital converter. The displacement gauge reading and the target effective pressing displacement gauge reading use the same single-count displacement amount of the hydraulic cylinder displacement sensor. When the pressure sampling latch does not return a pressure gauge number, a pressure missing flag is written to the pressure field corresponding to the current scan cycle number; when the displacement sampling latch does not return a displacement gauge number, a displacement missing flag is written to the displacement field corresponding to the current scan cycle number; scan slots with pressure missing flags or displacement missing flags are not included in the calculation of the crimp response slope word in S2. In S13, the current scan cycle number is used as the scan slot address, and the pressure field, displacement field and target field are written in the scan slot corresponding to the current scan slot address; the pressure field is written with the pressure gauge number, the displacement field is written with the displacement gauge number, and the target field is written with the target effective crimping displacement gauge number. After writing is complete, the scan slots are read in ascending order of scan slot address, and the scan slot address, pressure field, displacement field and target field are connected in a fixed field order to generate a pressure-displacement scan chain; When a scanning slot has a missing pressure flag, a missing displacement flag, a missing target flag, or a missing displacement calibration flag, the pressure-displacement scanning chain retains the scanning slot address and the corresponding flag. When the corresponding flag is read in subsequent steps, the difference calculation for that scanning slot is skipped. When the same scan slot address is written repeatedly, the pressure field, displacement field and target field written later are retained, so that the pressure-displacement scan chain contains only one identical scan slot address. Through this implementation method, the target effective pressing displacement is converted into the target effective pressing displacement meter number with the same counting unit as the displacement field. The pressure meter number and the displacement meter number are constrained to the same scanning slot by the same scanning cycle number. Subsequently, S2 can perform pressure difference, displacement difference and pressing response slope word calculation according to the scanning slot address. In practical applications: When the centralized manufacturing control terminal issues process number 15, the target displacement table records the effective pressing displacement of 4800 micrometers in the 15th row, the single-count displacement of the hydraulic cylinder displacement sensor is 2 micrometers, and the target effective pressing displacement meter number is written as 2400; when the scanning cycle number changes from 102 to 103, the pressure displacement intelligent sensing system converts the pressure meter number 3180 and the displacement meter number 1265, and writes the pressure field 3180, the displacement field 1265 and the target field 2400 into the scanning slot address 103. This scanning slot in the pressure displacement scanning chain is available for S2 to read.

[0018] S2. Perform sensor consistency sorting on the pressure-displacement scanning chain through the intelligent sensing system, bind pressure scanning words and displacement scanning words according to the same scanning cycle, and generate a pressing response slope chain by dividing the pressure difference between adjacent scanning cycles by the displacement difference; execute the wild binary change point detection algorithm on the pressing response slope chain, generate scanning segments according to the combination of scanning positions, scan candidate segment positions one by one and calculate the absolute value of the difference between the mean values ​​of the left and right slopes, and write the candidate segment position ranked first as the pressing change point; This implementation converts the pressure-displacement scan chain into a pressure response slope chain, and determines the pressure change point from the pressure response slope chain, ensuring that the short-range pressure relief action falls within the scan cycle where the pressure-displacement response changes. The intelligent pressure-displacement sensing system first eliminates scan slots with missing markers, then calculates the integer ratio of pressure change to displacement change for adjacent scan slots. Subsequently, it constructs wild scan segments using the scan slot addresses, compares the difference in the average slope values ​​of the left and right sides bit by bit within each wild scan segment, and finally writes the candidate segmentation bit ranked first in segmentation cost value into the change point register. This implementation includes the following steps: S21 is used to convert the pressure field and displacement field into a crimp response slope chain that can be read by the change point detection; the pressure and displacement intelligent sensing system reads the pressure and displacement scanning chain and reads the pressure field and displacement field in ascending order of the scanning slot address; when the scanning slot has a pressure missing flag, displacement missing flag, target missing flag or displacement calibration missing flag, the corresponding scanning slot does not participate in the crimp response slope word calculation. The crimp response slope word of the initial scan slot address is written to zero; the pressure difference value of the subsequent scan slot address is obtained by subtracting the previous pressure field from the current pressure field, and the displacement difference value is obtained by subtracting the previous displacement field from the current displacement field. When the displacement difference is zero, the current pressure response slope word follows the previous pressure response slope word; when the displacement difference is non-zero, first multiply the pressure difference by the slope amplification factor, then divide by the absolute value of the displacement difference. If the remainder is zero, take the integer quotient; if the remainder is non-zero, take the integer quotient plus one; when the pressure difference and displacement difference have the same sign, the current pressure response slope word is written as a positive integer; when the pressure difference and displacement difference have different signs, the current pressure response slope word is written as a negative integer. The slope amplification factor is stored in the slope ratio register of the programmable logic controller to retain the number of significant digits after integer division; each local crimp response slope word is written in ascending order of the scan slot address to generate a crimp response slope chain. S22 is used to generate wild scan segments by deterministic address operation, so that the scan segments come from the pressure displacement scan chain itself rather than manually specified positions; the pressure displacement intelligent sensing system reads the chain length of the crimp response slope chain, which is the number of scan slots participating in the calculation of the crimp response slope word; when the chain length is zero or one, the wild scan segment table is written with an empty table flag, and the change point register is written with an invalid flag. When the chain length is greater than one, the chain length is used as the base for the remainder operation. Two sets of address operations are performed on each scan slot address involved in the calculation: The first set is the square of the scan slot address plus the scan slot address, modulo the chain length. If the remainder is zero, it is rewritten as the chain length, generating the wild left end; The second set is the square of the scan slot address plus twice the scan slot address, modulo the chain length. If the remainder is zero, it is rewritten as the chain length, generating the wild right end. When the wild left end is smaller than the wild right end, write the wild left end and the wild right end into the wild scan segment table; when the wild left end is larger than the wild right end, swap the wild left end and the wild right end and write them into the wild scan segment table; when the wild left end is equal to the wild right end, do not write them into the wild scan segment table; when the same wild scan segment is generated repeatedly, retain the first write record. S23 is used to calculate the segmentation cost of candidate segmentation positions within each wild scan segment; the pressure displacement intelligent sensing system reads the wild scan segment table item by item; for each scan segment, the candidate segmentation position starts from the left end of the scan segment and ends at the position before the right end of the scan segment, ensuring that there are pressure response slope words on both the left and right sides of the candidate segmentation position. For a candidate segmentation bit, first accumulate the crimp response slope words from the left end of the scanned segment to the candidate segmentation bit, and divide by the number of terms on the left. If the remainder is zero, take the integer quotient. If the remainder is non-zero, take the integer quotient by the absolute value, add one, and restore the sign to generate the average slope value on the left. Then accumulate the crimp response slope words from the next bit of the candidate segmentation bit to the right end of the scanned segment, and generate the average slope value on the right according to the same integer division rule. Finally, the average slope of the left side is subtracted from the average slope of the right side, and the absolute value of the difference is taken to generate the segmentation cost value; each candidate segmentation position and its corresponding segmentation cost value are written into the candidate segmentation table according to the same scan segment number. S24 is used to select a unique pressing change point from the candidate segmentation table and hand the result over to the programmable logic controller; the pressure displacement intelligent sensing system reads the candidate segmentation table and first arranges the candidate segmentation positions from largest to smallest according to the segmentation cost; When the segmentation values ​​are the same, the candidate segmentation bits are arranged in ascending order. After sorting, the first candidate segmentation bit is read as the crimping change point, and the scan slot address corresponding to the crimping change point is written into the change point register of the programmable logic controller. When the candidate segmentation table is empty, an invalid flag is written to the change point register; when the crimping change point is the first or last position of the crimping response slope chain, an invalid flag is written to the change point register, and subsequent S3 will not perform short-range decompression to avoid out-of-bounds errors when reading the address of the previous or next scan slot of the crimping change point. In this implementation, the pressure displacement scanning chain is first converted into an integer-based pressing response slope chain, and then the location of the slope structure change is found by the wild scanning sub-segment derived from the scanning slot address. The pressing change point is directly written into the change point register for short-range pressure relief reading. In practical applications: all scan slot addresses 101 to 108 contain pressure and displacement fields. S21 calculates the pressure response slope chain based on adjacent scan slots. When the chain length is 8, the left wild end is obtained by squaring the scan slot address 103 and adding it to the scan slot address, then taking the remainder after dividing by 8. The right wild end is obtained by squaring the scan slot address 103 and adding it to twice the scan slot address, then taking the remainder after dividing by 8. The two form a wild scan segment. S23 calculates the difference in the average slope of the left and right sides bit by bit within the wild scan segment. If the segmentation cost value corresponding to scan slot address 105 is ranked first, then S24 writes scan slot address 105 into the change point register. S3 uses scan slot address 105 as the short-range pressure release trigger position.

[0019] S3. During the scanning cycle corresponding to the point of change in pressing, output the short-range pressure relief control word according to the ladder diagram logic. The hydraulic valve group reduces the cylinder pressure and maintains the mold clamping. The edge IoT acquisition terminal reads the reverse change of the displacement scanning word and generates the equipment springback displacement word. This implementation method transforms the crimping change point into a short-range pressure release process directly executed by the ladder diagram, and extracts the equipment springback displacement word during the pressure release. The crimping change point comes from the change point register, and the pressure field and displacement field come from the pressure-displacement scan chain. The scan slot address in the pressure-displacement scan chain increments according to the scan cycle. The pressure field is an integer number after pressure analog-to-digital conversion, and the displacement field is an integer number after cylinder displacement analog-to-digital conversion. Short-range pressure release is only executed when the crimping change point has the previous scan slot address and the next scan slot address. Boundary positions, missing fields, and division by zero are all converted into definite register write results to avoid the control process from remaining in an unexecutable state. The implementation process of this implementation method includes the following steps: S31 is used to convert the scanning slot address corresponding to the crimping change point into the pressure relief start displacement meter number and the pressure relief differential meter number; read the crimping change point scanning slot address in the change point register. The change point register uses signed integers for storage, and a negative one indicates an invalid flag. When the address of the pressure change point scanning slot is equal to the address of the first scanning slot, the address of the last scanning slot, or negative one in the pressure displacement scanning chain, the change point register remains negative one, the pressure release enable bit is written to zero, and short-range pressure release does not enter S32. When the crimping change point scanning slot address has the previous scanning slot address and the next scanning slot address, the displacement field of the crimping change point scanning slot address is read and written into the pressure relief start displacement register to form the pressure relief start displacement meter number. Simultaneously read the pressure field of the previous scan slot address and the pressure field of the next scan slot address. When both are integer pressure gauge numbers, subtract the pressure field of the next scan slot address from the pressure field of the previous scan slot address to generate the pressure relief differential pressure gauge number and write it into the pressure relief differential pressure register. When any pressure field or displacement field has a sampling missing flag, the change point register is written with a negative one, the pressure relief enable bit is written with zero, and the pressure relief start displacement register and pressure relief difference register are not rewritten. S32 is used to convert the pressure differential gauge digital value into the pressure scan gauge digital value that the ladder diagram pressure relief counter can decrement and execute; read the pressure field of the pressure differential register, the previous scan slot address, and the left and right scan slot addresses of the wild scan segment where the pressure change point is located. The number of wild scan slots is generated by subtracting the left scan slot address from the right scan slot address and then adding one. The number of wild scan slots serves as the upper bound of the pressure relief scanner number. When the pressure field of the previous scan slot address is zero, the pressure relief scanner number is written as one. When the pressure field of the previous scan slot address is a positive integer and the pressure differential meter reading is zero or a negative integer, the pressure differential meter reading is written as 1; when the pressure field of the previous scan slot address is a positive integer and the pressure differential meter reading is a positive integer, the pressure differential meter reading is divided by the pressure field of the previous scan slot address. If the remainder is zero, the integer quotient is taken; if the remainder is non-zero, the integer quotient is added to one to obtain the pressure differential meter reading. When the pressure relief scanner number is greater than the number of scanning slots in the wild scanning segment, the pressure relief scanner number is rewritten to the number of scanning slots in the wild scanning segment; the pressure relief scanner number is written into the pressure relief counter of the ladder diagram, and the pressure relief enable bit is written to one, so that S33 can read it by decreasing the number of slots according to the scan cycle. S33 is used to convert the pressure relief scan counter digital value into the coil energization state of the hydraulic valve group; the ladder diagram reads the pressure relief enable bit and pressure relief counter at the start edge of each programmable logic controller scan cycle; When the pressure relief enable bit is one and the pressure relief counter is a positive integer, the ladder diagram writes one to the clamping coil potential, zero to the pressurizing coil potential, and one to the pressure relief coil potential, generating a short-range pressure relief control word, and decrements the pressure relief counter by one at the end of the same scan cycle. After the hydraulic valve assembly reads the short-range pressure relief control word, the clamping oil circuit remains open, the pressurizing oil circuit is closed, and the pressure relief oil circuit is connected. During the scan cycle when the pressure relief counter decrements to zero, the ladder diagram writes the pressure relief end scan cycle number into the pressure relief end register, and simultaneously writes the pressure relief enable bit and the pressure relief coil on-state potential to zero, so that S4 can read the pressure relief end scan cycle number and enter the original position repressurization. If the initial value written to the pressure relief counter is one, the short-range pressure relief control word will only be output within one scan cycle. S34 is used to extract the device rebound displacement word from the displacement field during short-range decompression; the edge IoT acquisition terminal reads the displacement field of the current scan slot address in each scan cycle when the decompression enable bit is one, and reads the decompression start displacement meter number in the decompression start displacement register; The displacement field of the current scan slot address is subtracted from the displacement meter value at the pressure relief starting point to generate the displacement meter value for this cycle. When the back-off displacement meter reading for this period is a positive integer, the back-off displacement meter reading for this period is accumulated into the springback accumulation register; when the back-off displacement meter reading for this period is zero or a negative integer, the springback accumulation register retains its original integer value. When the displacement field of the current scan slot address has a sampling missing flag, the bounce accumulation register retains its original integer value and writes the current scan slot address into the bounce missing scan slot register; after the release enable bit changes from one to zero, the integer value of the bounce accumulation register is read and written as the device bounce displacement word, which is used for the bounce bit sequence reading of the three-component displacement status word in S5. Through the above processing, the starting point of short-range pressure relief, the number of continuous scan cycles, the valve coil status, and the equipment springback displacement word are all directly generated by the pressure displacement scan chain, the change point register, and the wild scan segment; the equipment springback displacement word represents the cumulative back-back response formed by the displacement meter digit relative to the pressure relief starting point during the pressure relief period, and does not represent the end-point back-back amount of a single scan cycle at the end of the pressure relief; when the pressure change point is at the boundary, the pressure field is missing, the displacement field is missing, the pressure differential meter digit is not a positive integer, or the pressure field of the previous scan slot address is zero, a definite output is formed according to the register writing rules; In practical applications: the scanning slot address of the crimping change point is 120, the scanning slot address of the left end of the wild scanning segment is 113, and the scanning slot address of the right end of the wild scanning segment is 126, so the number of scanning slots in the wild scanning segment is 14; the system reads the displacement field of the 120th scanning slot as the pressure relief starting point displacement meter number, subtracts the pressure field of the 121st scanning slot from the pressure field of the 119th scanning slot to obtain the pressure relief differential meter number, writes the converted pressure relief scanning meter number into the pressure relief counter, the ladder diagram outputs the short-range pressure relief control word during the period when the pressure relief counter is not zero, the edge IoT acquisition end accumulates the positive integer back displacement cycle by cycle, and after the pressure relief counter is zeroed, the device rebound displacement word is formed and handed over to the subsequent in-situ repressurization and three-component displacement state calculation and reading.

[0020] S4. After the short-range pressure relief ends, the in-situ pressure control word is output according to the functional diagram step relationship. The hydraulic valve group resumes pressurization. The edge IoT acquisition terminal reads the advance amount of the displacement scan word before the pressure scan word is incremented again and generates the fitting gap displacement word. This implementation method separates the displacement advancement after the short-range pressure release from the total cylinder displacement into a separate contact gap displacement value. Each scan slot in the pressure-displacement scan chain consists of a scan slot address, a pressure field, a displacement field, and a target field. The scan slot address corresponds to the scan cycle number of the programmable logic controller. The pressure field is an integer digit after pressure analog-to-digital conversion, and the displacement field is an integer digit after cylinder displacement analog-to-digital conversion. The displacement field and the target effective pressing displacement digit use the same single-count displacement value from the cylinder displacement sensor. After the short-range pressure release, the function chart step register does not directly enter the continued pressing phase. Instead, it first maintains clamping and performs in-situ repressing. By utilizing the scan cycle where the pressure field changes from non-incrementing to positive integer incrementing, the displacement consumed before the mold re-fits is deduced. Specifically, the following steps are included: S41 is used to determine the displacement starting point of in-situ repressurization and switch the short-range pressure relief step to the in-situ repressurization step; read the pressure relief end scan cycle number in the pressure relief end register and use the pressure relief end scan cycle number as the repressurization start scan slot address; When the address of the pressure start scanning slot exists in the pressure displacement scanning chain and the displacement field of the pressure start scanning slot address is an integer displacement meter number, the displacement field of the pressure start scanning slot address is written into the pressure start displacement register to generate the pressure start displacement meter number. Then, the function chart step register is read, the pressure relief step bit is written to zero, and the pressure recovery step bit is written to one, so that the control sequence changes from the short-range pressure relief step to the in-situ pressure recovery step. When the pressure release end register is empty, the pressure re-pressurization start scan slot address does not exist, or the displacement field of the pressure re-pressurization start scan slot address has a sampling missing flag, the pressure re-pressurization step is written to zero, the pressure re-pressurization start displacement register retains its original integer value, the bonding gap missing flag is written to one, and subsequent bonding gap displacement words are not generated. S42 is used to convert the repressing step into an in-situ repressing control word that can be executed by the hydraulic valve group, and to keep the mold clamped in a state from being released; the function diagram reads the repressing step at the beginning edge of each programmable logic controller scan cycle; When the repressurization step is one, the function diagram writes the pressure relief coil potential to zero, the pressure increase coil potential to one, and the clamping coil potential to one, and combines them to generate the in-situ repressurization control word, and writes the in-situ repressurization control word into the hydraulic valve group output image area. After the hydraulic valve group reads the original pressure control word, the pressure relief oil circuit is closed, the pressure increase oil circuit is connected, and the clamping oil circuit remains open, so that the oil cylinder resumes loading in the crimping direction while the mold is still clamping the insulator fitting. When the repressurization step is zero, the function diagram does not output the in-situ repressurization control word; when the pressure relief coil feedback position, pressure increase coil feedback position, clamping coil feedback position are inconsistent with the corresponding on-state potential, the valve group feedback abnormality flag is written as 1, the repressurization step is written as zero, and the edge IoT acquisition terminal stops executing the pressure increment word calculation for this cycle. S43 is used to determine the scanning slot address where the bonding gap consumption ends by the first positive integer increment of the adjacent pressure field; in each scanning cycle with a re-pressure step of one, the edge IoT acquisition terminal reads the pressure field of the current scanning slot address and the pressure field of the previous scanning slot address, and subtracts the pressure field of the previous scanning slot address from the pressure field of the current scanning slot address to generate the pressure increment word for this cycle. When the pressure increment word of this cycle is zero or a negative integer, it means that the cylinder displacement is still used for mold backing or structural clearance consumption in the current scanning cycle. The edge IoT acquisition terminal writes the current scanning slot address into the repressing scan record register, keeps the repressing step bit at one, and continues to read the next scanning slot address. When the periodic pressure increment word is a positive integer, it indicates that the current scan slot has entered the pressure recovery stage. The previous scan slot address is the displacement endpoint before the pressure is re-increased. The edge IoT acquisition terminal writes the previous scan slot address into the gap endpoint register to generate the gap endpoint scan slot address and writes the repressurization step bit to zero. If the pressure field of the current scan slot address or the pressure field of the previous scan slot address has a sampling missing flag, the pressure increment word for this cycle will not be generated. The current scan slot address will be written to the complex pressure missing scan slot register, and the complex pressure step will be kept and transferred to the next scan cycle. If a positive integer pressure increment word for this cycle still does not appear when the pressure displacement scan chain is continuously scanned to the end, the fitting gap missing flag will be written as 1, and the complex pressure step will be written as 0. S44 is used to convert the displacement advance amount corresponding to the gap end scan slot address into the fitting gap displacement word; read the gap end scan slot address in the gap end register, and at the same time read the complex pressure start displacement meter number in the complex pressure start displacement register; When the gap end scanning slot address exists and the displacement field of the gap end scanning slot address is an integer displacement meter number, the fitting gap displacement meter number is generated by subtracting the overpressure start displacement meter number from the displacement field of the gap end scanning slot address. When the number of the bonding gap displacement meter is a positive integer or zero, the number of the bonding gap displacement meter is written into the bonding gap register to form the bonding gap displacement word; when the number of the bonding gap displacement meter is a negative integer, the bonding gap displacement word is written to zero to avoid reverse jitter from entering the effective pressing displacement estimation. When the gap end scanning slot address does not exist, the displacement field of the gap end scanning slot address has a sampling missing flag, or the digital value of the complex pressure start displacement meter does not exist, the mating gap register is not rewritten, and the mating gap missing flag is written as 1. After the gap displacement word is written, it is used to read the gap position sequence of the three-component displacement status word in S5. The position sequence of the three-component displacement status word is fixed as the effective position sequence, the springback position sequence, and the gap position sequence. In this embodiment, the fitting gap displacement word is not determined by the duration of repressurization, the external pressure threshold or empirical parameters, but by the short-range pressure relief end scan cycle, the function graph step state, the difference between adjacent pressure fields and the gap end scan slot address. When the pressure field first shows a positive integer increment, the current scan slot has begun to recover the force. Therefore, the address of the previous scan slot is used as the address of the gap end scan slot. This process separates the interval where "the displacement has advanced but the pressure has not yet been re-established" from the total displacement. Subsequently, when S5 calculates the effective pressing displacement estimation word, it subtracts the equipment springback displacement word and the bonding gap displacement word from the displacement field corresponding to the pressing change point. In practical applications: When the pressure relief end scan cycle number is 128, the system reads the displacement field of the 128th scan slot as the displacement meter number of the pressure recovery start point. The function diagram writes the pressure relief step to zero and the pressure recovery step to one. The hydraulic valve group keeps the clamping oil circuit connected and connects the pressurization oil circuit. The edge IoT acquisition terminal calculates the pressure increment word of this cycle cycle by cycle starting from the 129th scan slot. When the pressure field of the 134th scan slot minus the pressure field of the 133rd scan slot results in a positive integer, the address of the 133rd scan slot is written to the gap end register. Then, the displacement field of the 128th scan slot is subtracted from the displacement field of the 133rd scan slot to generate the fitting gap displacement word and write it to the fitting gap register.

[0021] S5. Execute the volumetric Kalman filter algorithm based on the displacement scanning word, equipment springback displacement word, and bonding gap displacement word corresponding to the crimping change point. Generate bidirectional volume points with three-component displacement state words. Generate effective crimping displacement estimation word through state propagation and arithmetic mean calculation. Rewrite the crimping action output state according to the sign of the difference between the effective crimping displacement estimation word and the target effective crimping displacement, and send it back to the centralized manufacturing control terminal. This implementation method decomposes the cylinder displacement field at the point of change in pressing into three deterministic components: effective pressing displacement, equipment springback displacement, and fitting gap displacement. The effective pressing displacement estimate is converted into a mutually exclusive output bit that can be executed by a programmable logic controller (PLC). The displacement field, equipment springback displacement, fitting gap displacement, and target effective pressing displacement value in the pressure displacement scan chain are all expressed using integer digits. The displacement field and the target effective pressing displacement value use the same single-count displacement value from the same cylinder displacement sensor. The bit order of the three-component displacement status word is fixed as effective bit order, springback bit order, and gap bit order. Subsequent volume point generation, propagation, and write-back are all read according to this bit order. This implementation process includes the following steps: S51 is used to form the three-component displacement status word of the volumetric Kalman filter algorithm; read the pressure change point scan slot address in the change point register, and read the displacement field of the pressure change point scan slot address from the pressure displacement scan chain; at the same time, read the device springback displacement word in the device springback register and the bonding gap displacement word in the bonding gap register. When the address of the crimping change point scanning groove is negative one, the displacement field has a sampling missing flag, the equipment springback displacement word has a missing flag, or the bonding gap displacement word has a missing flag, the status missing flag is written as one, and the three-component displacement status word is not generated. When the displacement field, the equipment springback displacement character, and the bonding gap displacement character are all integer numbers, the initial effective pressing displacement calculation value is obtained by subtracting the equipment springback displacement character from the displacement field and then subtracting the bonding gap displacement character. When the initial effective pressing displacement calculation value is a negative integer, the initial effective pressing displacement word is written as zero; when the initial effective pressing displacement calculation value is zero or a positive integer, the initial effective pressing displacement word is written as the initial effective pressing displacement calculation value. Then, the initial effective pressing displacement word is written into the effective bit sequence, the equipment springback displacement word is written into the springback bit sequence, and the bonding gap displacement word is written into the gap bit sequence to generate a three-component displacement status word for S52 to read. S52 is used to generate six bidirectional volume points according to the three-dimensional symmetric sampling rules of the volumetric Kalman filter algorithm; read the effective position sequence, rebound position sequence and gap position sequence in the three-component displacement status word; perform a multiplication operation of three on the component number of each position sequence to generate the square root integer of the corresponding position sequence; The square root of an integer is obtained by incremental trial calculation: the trial integer starts from zero and increments by one. Each time the square value of the trial integer is calculated, if the square value is less than the radicand, the increment continues. If the square value is greater than or equal to the radicand, the increment stops and the trial integer at the point of termination is written as the volume radius word of the corresponding position. Subsequently, six bidirectional volume points are generated around the three-component displacement state word: the positive effective volume point simply adds the effective volume radius word to the effective position sequence, and the negative effective volume point simply subtracts the effective volume radius word from the effective position sequence; the positive rebound volume point simply adds the rebound volume radius word to the rebound position sequence, and the negative rebound volume point simply subtracts the rebound volume radius word from the rebound position sequence. For a positive gap volume point, only the gap position number is added to the gap volume radius word; for a negative gap volume point, only the gap position number is subtracted from the gap volume radius word. The position number not operated on retains the original integer value in the three-component displacement state word. When the negative integer is obtained by the reverse subtraction, the corresponding position number is written as zero. S53 is used to propagate six bidirectional volume points into six propagation volume points, so that the disturbances of the springback sequence and the gap sequence are re-acted on the effective sequence; read the six bidirectional volume points one by one; for each bidirectional volume point, read the springback sequence and the gap sequence in the bidirectional volume point, and read the displacement field of the scanning slot address of the crimping change point. Subtract the rebound position sequence of the current bidirectional volume point from the displacement field, and then subtract the gap position sequence of the current bidirectional volume point to obtain the calculated value of the propagation effective component; When the calculated value of the propagation effective component is a negative integer, the propagation effective component is written as zero; when the calculated value of the propagation effective component is zero or a positive integer, the propagation effective component is written as the calculated value of the propagation effective component. Then, the propagation effective components are written into the effective bit sequence, the rebound bit sequence of the current bidirectional volume point is written into the rebound bit sequence, and the gap bit sequence of the current bidirectional volume point is written into the gap bit sequence to generate a propagation volume point; after all six bidirectional volume points have completed the same propagation, six propagation volume points are obtained for S54 to calculate the average and residual closure reading. S54 is used to converge six propagation volume points into an effective compression displacement estimation word; read the effective propagation components of the six propagation volume points and add them together to obtain the effective propagation component sum value; Divide the sum of the effective propagation components by six. If the remainder is zero, take the integer quotient. If the remainder is non-zero, take the integer quotient plus one to generate the intermediate effective compression displacement word. The weights of the six propagation volume points are all one divided by six, which comes from the six-point symmetrical sampling rule of the three-dimensional volume Kalman filter algorithm. No additional empirical weights are set. Then, the displacement field, equipment springback displacement word, bonding gap displacement word, and intermediate effective pressing displacement word of the crimping change point scanning slot address are read. The equipment springback displacement word, bonding gap displacement word, and intermediate effective pressing displacement word are subtracted from the displacement field to generate the closed residual word. When the closed residual word is zero or a positive integer, the effective compression displacement estimation word is generated by adding the closed residual word to the middle effective compression displacement word; when the closed residual word is a negative integer, the absolute value of the closed residual word is subtracted from the middle effective compression displacement word. If the result of the subtraction is a negative integer, the effective compression displacement estimation word is written as zero; if the result of the subtraction is zero or a positive integer, it is written as the effective compression displacement estimation word. S55 is used to convert the effective crimping displacement estimation word into the crimping action output state and write it back to the centralized manufacturing control terminal; read the target effective crimping displacement meter number in the target field of the pressure displacement scan chain; subtract the target effective crimping displacement meter number from the effective crimping displacement estimation word to generate the target difference word; When the target difference word is a negative integer, the output bit is written to 1 when the voltage is applied, the output bit is written to 0 when the voltage is held, and the output bit is written to 0 when the voltage is released; when the target difference word is zero, the output bit is written to 1 when the voltage is held, the output bit is written to 0 when the voltage is applied, and the output bit is written to 0 when the voltage is released; when the target difference word is a positive integer, the output bit is written to 1 when the voltage is released, the output bit is written to 0 when the voltage is applied, and the output bit is written to 0 when the voltage is held. Then, the insulator crimping process number is read, and the insulator crimping process number is used as the record address of the centralized manufacturing control terminal. The current scan cycle number, the effective crimping displacement estimation word, and the output bit that is currently written to 1 are written. When a historical record already exists at the same record address in the centralized manufacturing control terminal, the scan cycle number in the historical record is read. If the current scan cycle number is greater than the scan cycle number in the historical record, the historical record is overwritten. If the current scan cycle number is less than or equal to the scan cycle number in the historical record, the historical record is retained. In this implementation, the output state of the crimping action is not directly determined by the total displacement of the hydraulic cylinder, but by the effective crimping displacement estimate formed by subtracting the equipment springback displacement word and the fitting gap displacement word from the displacement field of the crimping change point; the position order of the effective position sequence, springback position sequence and gap position sequence is fixed, the generation rules of the six bidirectional volume points are fixed, the calculation source of the propagation effective component is fixed, the positive and negative processing of the closing residual word is fixed, the output bits are written mutually exclusively, and the feedback record is updated according to the insulator crimping process number and the current scanning cycle number; In practical applications: When the scanning slot address of the crimping change point is 120, the system reads the displacement field of the 120th scanning slot, and reads the equipment springback displacement word and the bonding gap displacement word, first generating a three-component displacement status word; then, positive volume points and reverse volume points are generated on the effective position sequence, springback position sequence and gap position sequence respectively, and six propagation effective components are obtained through propagation; the average of the six propagation effective components is used to obtain the intermediate effective crimping displacement word, which is then corrected by the closed residual word to the effective crimping displacement estimation word; after subtracting the effective crimping displacement estimation word from the target effective crimping displacement meter number, it is written to the pressurization output bit, holding output bit or depressurization output bit, and the effective crimping displacement estimation word and the currently written one output bit are written back to the centralized manufacturing control terminal.

[0022] Working principle: The centralized manufacturing control terminal first issues the target effective crimping displacement according to the insulator crimping process. The pressure displacement intelligent sensing system synchronously collects pressure and cylinder displacement within the scanning cycle of the programmable logic controller, forming a pressure displacement scanning chain. Then, it calculates the crimping response slope based on the pressure and displacement changes in adjacent scanning cycles, and determines the location where the crimping state changes abruptly through wild binary change point detection. At this location, short-range pressure release is triggered, and the reverse displacement change is read to form the equipment rebound displacement word. Then, in-situ re-pressurization is performed, and the displacement advance before the pressure increases again is read to form the fitting gap displacement word. Finally, the equipment rebound displacement and fitting gap displacement are subtracted from the crimping change point displacement, and the effective crimping displacement estimation word is calculated through volumetric Kalman filtering. Based on this, the pressurization, holding, or depressurization status is output and simultaneously transmitted back to the centralized manufacturing control terminal. On the insulator fitting crimping production line, what is visible on the surface when the hydraulic cylinder advances is the total displacement, but this includes both the actual crimping deformation of the fitting and the displacement consumed by the mold's springback and the clamp's re-fitting. This solution, when crimping to the point of state change, does not directly take the hydraulic cylinder displacement as the effective crimping displacement, but instead allows the equipment to briefly release pressure to measure the springback amount, and then re-pressurize in situ to measure the gap consumption. Subsequently, these two parts are subtracted from the total displacement to obtain an effective displacement that is closer to the actual crimping formation. In this way, the production line can continue to pressurize, maintain, or depressurize according to the actual effective crimping displacement in each scanning cycle, which is suitable for continuous processing scenarios where multiple crimping machines are coordinated and managed by a centralized manufacturing control terminal.

[0023] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A closed-loop industrial automatic control method for pressure displacement during insulator crimping process, characterized in that, include: S1. Obtain the target effective crimping displacement issued by the centralized manufacturing control terminal according to the insulator crimping process number. The edge IoT acquisition terminal synchronously reads the pressure analog quantity and the cylinder displacement analog quantity within the scanning cycle of the programmable logic controller, and generates a pressure displacement scanning chain through analog-to-digital conversion. S2. Perform sensor consistency sorting on the pressure-displacement scanning chain through the intelligent sensing system, bind pressure scanning words and displacement scanning words according to the same scanning cycle, and generate a pressing response slope chain by dividing the pressure difference between adjacent scanning cycles by the displacement difference; execute the wild binary change point detection algorithm on the pressing response slope chain, generate scanning segments according to the combination of scanning positions, scan candidate segment positions one by one and calculate the absolute value of the difference between the mean values ​​of the left and right slopes, and write the candidate segment position ranked first as the pressing change point; S3. During the scanning cycle corresponding to the point of change in pressing, output the short-range pressure relief control word according to the ladder diagram logic. The hydraulic valve group reduces the cylinder pressure and maintains the mold clamping. The edge IoT acquisition terminal reads the reverse change of the displacement scanning word and generates the equipment springback displacement word. S4. After the short-range pressure relief ends, the in-situ pressure control word is output according to the functional diagram step relationship. The hydraulic valve group resumes pressurization. The edge IoT acquisition terminal reads the advance amount of the displacement scan word before the pressure scan word is incremented again and generates the fitting gap displacement word. S5. Execute the volumetric Kalman filter algorithm based on the displacement scanning word, equipment springback displacement word, and bonding gap displacement word corresponding to the crimping change point. Generate bidirectional volume points with three-component displacement state words. Generate effective crimping displacement estimation word through state propagation and arithmetic mean operation. Rewrite the crimping action output state according to the sign of the difference between the effective crimping displacement estimation word and the target effective crimping displacement, and send it back to the centralized manufacturing control terminal.

2. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 1, characterized in that: S1 includes: S11. The centralized manufacturing control terminal writes the insulator crimping process number as an unsigned integer into the process register. The programmable logic controller uses the process register value as the row address of the target displacement table, reads the target effective crimping displacement recorded in micrometers, removes the target effective crimping bit, counts the displacement by the hydraulic cylinder displacement sensor, takes the integer quotient when the remainder is zero, and takes the integer quotient plus one when the remainder is non-zero, and generates the target effective crimping displacement meter number. S12. At the beginning edge of the scan cycle, increment the scan cycle counter to generate the current scan cycle number. Simultaneously write the current scan cycle number to the pressure sampling latch and the displacement sampling latch. The pressure and displacement intelligent sensing system maintains the pressure analog quantity and the cylinder displacement analog quantity on the same latch edge, and generates the pressure gauge digital and displacement gauge digital respectively through analog-to-digital conversion. S13. Using the current scan cycle number as the scan slot address, write the pressure gauge number into the pressure field, the displacement gauge number into the displacement field, and the target effective pressing displacement gauge number into the target field. Then, read each scan slot in ascending order of the scan slot address to generate a pressure-displacement scan chain consisting of the scan slot address, pressure field, displacement field, and target field.

3. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 2, characterized in that: S2 includes: S21. The pressure displacement intelligent sensing system reads the pressure displacement scanning chain, reads the pressure field and displacement field according to the scanning slot address, writes zero to the crimping response slope word of the starting scanning slot address, subtracts the previous pressure field from the current pressure field to obtain the pressure difference value for the next scanning slot address, and subtracts the previous displacement field from the current displacement field to obtain the displacement difference value. When the displacement difference is zero, the previous crimping response slope word is used. When the displacement difference is non-zero, the current crimping response slope word is generated by dividing the pressure difference value by the displacement difference value. The crimping response slope chain is generated in ascending order of the scanning slot address. S22. The pressure displacement intelligent sensing system performs a wild binary change point detection algorithm on the crimp response slope chain. Using the chain length of the crimp response slope chain as the remainder base, the wild left end is generated by adding the square of the scan slot address to the scan slot address and taking the remainder. The wild right end is generated by adding twice the scan slot address to the square of the scan slot address and taking the remainder. The scan bit combination where the wild left end is less than the wild right end is written into the wild scan sub-segment table. The scan bit combination where the wild left end is greater than the wild right end is swapped and written into the wild scan sub-segment table.

4. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 3, characterized in that: S2 also includes: S23. For each scan segment in the wild scan segment table, scan the candidate segmentation position between the left end and the right end of the scan segment one by one. Calculate the arithmetic mean of the pressure response slope words from the left end of the scan segment to the candidate segmentation position to obtain the left slope mean. Calculate the arithmetic mean of the pressure response slope words from the next candidate segmentation position to the right end of the scan segment to obtain the right slope mean. Write the absolute value of the difference between the left slope mean and the right slope mean as the segmentation cost. S24. Arrange the candidate segmentation bits in descending order of segmentation value and ascending order of candidate segmentation bits. Read the first candidate segmentation bit in the sorted order as the crimping change point and write the scan slot address corresponding to the crimping change point into the change point register of the programmable logic controller.

5. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 4, characterized in that: S3 includes: S31. Read the scanning slot address corresponding to the pressure change point, write the displacement field of the corresponding scanning slot address as the pressure relief start point displacement meter number, and write the integer obtained by subtracting the pressure field of the next scanning slot address from the pressure field of the previous scanning slot address as the pressure relief differential meter number. S32. Divide the pressure field of the previous scan slot address by the pressure differential pressure gauge number. If the remainder is zero, take the integer quotient as the pressure differential pressure gauge number. If the remainder is not zero, take the integer quotient plus one as the pressure differential pressure gauge number. Write the pressure differential pressure gauge number into the pressure differential pressure counter of the ladder diagram.

6. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 5, characterized in that: S3 also includes: S33. The pressure relief counter decrements by one after each scan cycle. During the period when the pressure relief counter is not zero, the ladder diagram outputs a short-range pressure relief control word with the clamping coil potential at one, the pressurizing coil potential at zero, and the pressure relief coil potential at one, so that the hydraulic valve group shuts off the pressurizing oil circuit, connects the pressure relief oil circuit, and keeps the clamping oil circuit open. S34. During the period when the pressure relief counter is not zero, the edge IoT acquisition terminal reads the displacement field of each scanning cycle, subtracts the displacement field of the current cycle from the displacement meter number at the pressure relief start point to generate the displacement meter number of the current cycle, and accumulates the positive integers in the displacement meter number of the current cycle to generate the device rebound displacement word.

7. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 6, characterized in that: S4 includes: S41. During the scan cycle when the pressure relief counter returns to zero, read the displacement field of the corresponding scan slot address and write it as the displacement value of the pressure recovery start point. At the same time, write the pressure relief step bit to zero and the pressure recovery step bit to one in the function chart step register. S42. When the repressurization step is one, the function diagram outputs an in-situ repressurization control word with the pressure relief coil potential at zero, the pressure increase coil potential at one, and the clamping coil potential at one, so that the hydraulic valve group shuts off the pressure relief oil circuit, connects the pressure increase oil circuit, and keeps the clamping oil circuit open.

8. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 7, characterized in that: S4 also includes: S43. In each scanning cycle with a re-pressure step of one, the edge IoT acquisition terminal reads the pressure field of the current scanning slot address and the pressure field of the previous scanning slot address, and subtracts the two to generate the pressure increment word of the current cycle. When the pressure increment word of the current cycle is zero or a negative integer, it continues to be written to the next scanning slot. When the pressure increment word of the current cycle is a positive integer, the previous scanning slot address is written as the gap end scanning slot address, and the re-pressure step is written to zero. S44. Read the displacement field of the gap end scan slot address, and subtract the displacement meter number of the overpressure start point from the displacement field of the gap end scan slot address to generate the fitting gap displacement word.

9. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 8, characterized in that: S5 includes: S51. Read the displacement field, equipment springback displacement word, and bonding gap displacement word of the scanning slot address corresponding to the crimping change point. Subtract the equipment springback displacement word from the displacement field and then subtract the bonding gap displacement word to generate the initial effective crimping displacement word. When the calculation result is a negative integer, write the initial effective crimping displacement word to zero. The initial effective crimping displacement word, equipment springback displacement word, and bonding gap displacement word form a three-component displacement status word. S52. According to the capacitive Kalman filter algorithm, multiply the digit of each component in the three-component displacement state word by three and take the square root. When the remainder is zero, take the square root of the integer. When the remainder is non-zero, take the square root of the integer plus one to generate three capacitive radius words. Then, perform the addition and subtraction of the capacitive radius word on the corresponding component respectively. Write zero for the negative integer operation result to generate six bidirectional capacitive points. S53. Read the springback component and gap component for each bidirectional volume point. Subtract the springback component and then the gap component from the displacement field of the scanning slot address corresponding to the crimping change point to generate the propagation effective component. Write the negative integer calculation result as zero. The propagation volume point is composed of the propagation effective component, springback component and gap component.

10. The closed-loop industrial automatic control method for pressure displacement in the insulator crimping process according to claim 9, characterized in that: S5 also includes: S54. Add the effective propagation components of the six propagation volume points and divide by six. If the remainder is zero, take the integer quotient. If the remainder is not zero, take the integer quotient and add one to generate the intermediate effective pressing displacement word. Then, subtract the equipment springback displacement word, the bonding gap displacement word, and the intermediate effective pressing displacement word from the displacement field to generate the closed residual word. Finally, add the intermediate effective pressing displacement word and the closed residual word to generate the effective pressing displacement estimation word. S55. Subtract the target effective crimp displacement meter number from the effective crimp displacement estimation word to generate the target difference word. When the target difference word is a negative integer, write the pressurization output bit as 1. When the target difference word is zero, write the hold output bit as 1. When the target difference word is a positive integer, write the depressurization output bit as 1. Write the effective crimp displacement estimation word and the output bit to the centralized manufacturing control terminal using the insulator crimping process number as the record address.

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