Three-axis metal rubber blank winding device and method with online detection closed-loop control

Abstract

The present application relates to online detection closed loop control three shaft type metal rubber blank winding device and method, including workbench, workbench is equipped with clamping and driving mandrel rotation main shaft servo motor, the front side of main shaft servo motor is provided with by horizontal servo module drive left and right movement constant pitch stretching device, constant pitch stretching device is stretched to preset pitch state with metal spiral roll and is transported from front to back to guide wire mechanism, the top of mandrel is equipped with visual detection device, still includes vertical motion mechanism and quality detection device, vertical motion mechanism drives main shaft servo motor and mandrel and moves up and down along vertical, vertical motion mechanism is connected with industrial computer;Quality detection device sets up on the metal spiral roll conveying path of constant pitch stretching device, for detecting the unit quantity of metal spiral roll when metal spiral roll is conveyed at set conveying speed, the detection result is fed back to industrial computer.The present application improves the consistency, stability and automation degree of blank preparation.

Description

Technical Field

[0001] This invention belongs to the field of porous metal material processing and preparation technology, and particularly relates to a triaxial metal-rubber blank winding device and method with online detection and closed-loop control. Background Technology

[0002] Metal rubber is a highly elastic porous material made by winding metal wires into a spiral coil, stretching and winding the spiral coil at a fixed pitch into a blank, and then cold-stamping it. Due to its inherent high resilience, high damping, and fatigue resistance, metal rubber is now widely used in high-end equipment manufacturing fields such as aerospace, defense, and modern rail transportation.

[0003] The preparation process of metal rubber typically includes steps such as metal wire selection, metal spiral winding preparation, metal rubber blank winding, cold stamping, and post-processing. Among these, the metal rubber blank winding is a key process affecting the structural uniformity, dimensional consistency, and mechanical property stability of the finished part. During the blank winding process, the tension pitch of the metal spiral winding, the winding angle, the blank length, and the blank quality all affect the properties of the metal rubber after subsequent cold stamping. Therefore, it is necessary to achieve stable, continuous, and repeatable control over the blank winding process.

[0004] Existing metal-rubber blank winding equipment mostly adopts a two-axis winding method that combines horizontal feeding with spindle rotation. As the number of winding layers increases, the blank diameter gradually increases, while the guide wire exit position and the mandrel center position usually remain unchanged. This can easily cause changes in the tangent state between the metal spiral winding exit direction and the outer surface of the blank, forming an entry angle. This, in turn, causes spiral winding tension fluctuations and actual winding angle deviations, affecting the uniformity of blank laying and the consistency of molding.

[0005] Meanwhile, existing equipment still lacks the ability to perform online detection and closed-loop control of geometric parameters, actual length, and real-time quality during the blank winding process, making it difficult to compensate for problems such as blank length deviation, end accumulation, and quality errors in a timely manner. When the blank quality needs to be quantitatively controlled, it usually still relies on manual experience or weighing after winding, which is difficult to meet the real-time quality control requirements in continuous automated production. Summary of the Invention

[0006] The present invention addresses the problems existing in the prior art, namely, the technical problem to be solved by the present invention is to provide a triaxial metal-rubber blank winding device and method for online detection and closed-loop control.

[0007] To achieve the above objectives, the technical solution adopted by this invention is: a three-axis metal-rubber blank winding device with online detection and closed-loop control, comprising a worktable equipped with an industrial computer, a main spindle servo motor for clamping and driving the mandrel to rotate on the worktable, a fixed-pitch stretching device driven by a horizontal servo module to move left and right on the front side of the main spindle servo motor, the fixed-pitch stretching device stretching the metal spiral coil to a preset pitch state and conveying it from front to back to the wire guiding mechanism, a vision inspection device above the mandrel, and also including a vertical motion mechanism and a quality inspection device. The vertical motion mechanism drives the main spindle servo motor and the mandrel to move vertically up and down, and the vertical motion mechanism is electrically connected to the industrial computer; the quality inspection device is set on the metal spiral coil conveying path of the fixed-pitch stretching device, and is used to detect the unit quantity of the metal spiral coil when the metal spiral coil is conveyed at a set conveying speed, and feed the detection result back to the industrial computer.

[0008] Furthermore, the fixed-pitch stretching device includes a housing with a cover on top, and two sets of stretching rollers spaced apart along the conveying direction of the metal spiral coil and located above the cover. Each set of stretching rollers includes a fixed roller and a floating roller distributed on the left and right. The floating roller can open or close relative to the fixed roller. The fixed-pitch stretching device is provided with an elastic clamping mechanism for applying clamping force to the floating roller. Under the elastic clamping action of the elastic clamping mechanism, the floating roller can form an adaptive clamping gap with the change of the diameter of the metal spiral coil, so that the floating roller and the fixed roller form an elastic clamping of the metal spiral coil. An elastic friction layer is provided in the groove of the stretching roller.

[0009] Furthermore, the two sets of tension rollers are a low-speed roller group and a high-speed roller group distributed at the front and rear, respectively, and the low-speed roller group and the high-speed roller group operate at different angular velocities. In each set of tension rollers, the fixed roller and the floating roller are driven to rotate by tension drive motors installed in the box. The tension drive motor corresponding to the fixed roller is fixedly installed on the box cover or box body, and the tension drive motor corresponding to the floating roller is installed on a swing bracket. The swing bracket is rotatably installed on the box cover, so that the floating roller can open or close relative to the fixed roller. The elastic pressing mechanism is connected to the swing bracket to apply a pressing force to the swing bracket, so that the swing bracket drives the floating roller to press towards the fixed roller.

[0010] Furthermore, the quality inspection device includes an optical fiber sensor, an optical fiber amplifier, and a counting module. The optical fiber sensor is positioned on the metal spiral coil conveying path of the fixed-pitch stretching device, before the stretched metal spiral coil enters the mandrel winding area. The optical fiber amplifier is connected to the optical fiber sensor and is used to receive the detection signal fed back by the optical fiber sensor. Based on a preset detection threshold, it converts the light intensity change generated when the metal spiral coil passes the position of the quality inspection device into a switching pulse signal. The counting module is connected to the optical fiber amplifier and is used to effectively count the switching pulse signals and feed the effective counting results back to the industrial computer. The industrial computer calculates the number of metal spiral coil units entering the mandrel winding area based on the effective counting results fed back by the counting module and further calculates the real-time quality of the blank.

[0011] Furthermore, the discharge side of the fixed-pitch stretching device is also equipped with a wire-cutting mechanism. The wire-cutting mechanism includes a wire-cutting side bracket, a wire-cutting mounting bracket, and a pneumatic shear. The wire-cutting side bracket is installed on both sides of the fixed-pitch stretching device, and the wire-cutting mounting bracket is located between the upper ends of the two wire-cutting side brackets. The pneumatic shear is installed on the wire-cutting mounting bracket and is used to cut the stretched metal spiral coil. The industrial computer is also used to correct the effective winding stroke of the horizontal servo module in the next cycle based on the actual length of the blank obtained by the vision inspection device, and to calculate the real-time quality of the blank based on the number of metal spiral coils obtained by the quality inspection device. When the real-time quality of the blank reaches a preset value, the wire-cutting mechanism is controlled to cut the metal spiral coil.

[0012] Furthermore, the vision inspection device is used to acquire the contour image of the metal rubber blank during the winding process, and feeds back the real-time radius and actual length of the blank to the industrial computer. The industrial computer controls the vertical motion mechanism to drive the spindle servo motor and mandrel to move in the vertical direction according to the real-time radius change of the blank, so as to perform tangential position compensation, so that the metal spiral coil output by the wire guide mechanism remains tangential to the outer surface of the metal rubber blank.

[0013] Another technical solution adopted in this invention is: a triaxial metal-rubber blank winding method with online detection and closed-loop control, comprising the following steps:

[0014] Step 1: Input the target blank pitch, preset winding angle, target blank length, and target blank mass into the industrial computer;

[0015] Step 2: The fixed pitch stretching device stretches the metal spiral coil at a fixed pitch by the speed difference between two sets of stretching rollers, and during the normal winding process, the metal spiral coil passes through the detection position of the quality detection device at a set conveying speed.

[0016] Step 3: The vision inspection device acquires the outline image of the metal rubber blank and feeds back the real-time radius and actual length of the blank to the industrial computer.

[0017] Step four: While maintaining a stable conveying speed of the metal spiral coil and a stable detection speed at the quality inspection device, the industrial computer dynamically adjusts the rotation speed of the spindle servo motor based on the real-time radius of the blank to maintain the preset winding angle.

[0018] Step 5: The industrial computer controls the vertical motion mechanism to perform vertical tangential compensation based on the real-time radius of the blank, so that the metal spiral coil output by the wire guide mechanism remains tangential to the outer surface of the metal rubber blank.

[0019] Step 6: The industrial computer corrects the effective winding stroke of the horizontal servo module for the next cycle based on the error between the actual length of the blank and the target blank length.

[0020] Step 7: The quality inspection device detects the number of metal spiral coil units entering the mandrel winding area through fiber optic sensors, fiber optic amplifiers and counting modules. The industrial computer calculates the real-time quality of the blank based on the number of units.

[0021] Step 8: When the real-time quality of the blank reaches the target blank quality, the industrial computer controls the whole machine to stop winding and drives the wire cutting mechanism to cut the metal spiral coil.

[0022] Furthermore, in step six, the correction of the effective winding stroke of the horizontal servo module in the next cycle includes the following steps: (1) After the current formal winding segment ends, the vision inspection device obtains the actual length of the metal rubber blank; the industrial computer compares the actual length with the target blank length to obtain the length error; when the length error is within the preset allowable range, the industrial computer keeps the effective winding stroke of the next cycle unchanged; when the actual length is less than the target blank length, the industrial computer increases the effective winding stroke of the next cycle; when the actual length is greater than the target blank length, the industrial computer decreases the effective winding stroke of the next cycle; (2) When the horizontal servo module enters the reversing transition segment, the fixed pitch stretching device pauses the stretching of the wire, the horizontal servo module performs reversing geometric compensation, the wire guide mechanism switches the guiding direction, and the vertical motion mechanism performs reversing auxiliary compensation; the horizontal compensation stroke of the reversing transition segment is not included in the effective winding length of the metal rubber blank.

[0023] Furthermore, in step two, the ratio of the pitch of the stretched metal spiral coil to the speed of the high-speed pressure roller group and the low-speed pressure roller group can be expressed by the following calibration mapping relationship:

[0024]

[0025] In the formula: The pitch after stretching; The pitch compensation coefficient is obtained through experimental calibration. The initial pitch of the spiral coil. High-speed pressure roller angular velocity, The low-speed pressure wheel angular velocity; according to this formula, it can be seen that by adjusting... and The speed ratio allows for control of the tension pitch of the metal spiral coil;

[0026] The effective normal clamping force provided by the elastic clamping mechanism can meet the following requirements:

[0027]

[0028] In the formula: F is the effective normal clamping force provided by the elastic clamping mechanism, N is the equivalent axial tensile stiffness of the spiral coil, P is the pitch after tension, and P0 is the initial pitch of the spiral coil. It is the equivalent coefficient of friction between the elastic friction layer 205 and the metal spiral coil.

[0029] Furthermore, the specific implementation process of achieving length closed loop and horizontal module reversal compensation during the metal-rubber blank winding process is as follows: During the metal-rubber blank winding process, the movement process of the horizontal servo module includes a reversal transition section and a formal winding section; the reversal transition section is used to cooperate with the wire guide mechanism to complete the swing direction switching and wire feed direction adjustment before and after the horizontal servo module changes its movement direction; the formal winding section is used to lay the metal spiral coil after fixed pitch stretching on the mandrel or metal-rubber blank surface according to the preset winding angle.

[0030] Compared with the prior art, the present invention has the following advantages: The present invention uses a vertical motion mechanism to drive the main spindle servo motor and the mandrel to perform position compensation according to the change of the blank radius, so that the metal spiral coil output by the wire guide mechanism can continuously remain tangent to the outer surface of the blank, thereby reducing the influence of the wire entry angle and tension fluctuation on the winding angle from a physical structure perspective; In addition, the number of metal spiral coils entering the mandrel winding area is detected by a quality detection device, the blank quality is calculated in real time by an industrial computer, and the winding and wire cutting mechanisms are stopped in conjunction with the preset quality, thereby realizing online quantitative control of blank quality. Attached Figure Description

[0031] Figure 1 This is a three-dimensional structural schematic diagram of an embodiment of the present invention;

[0032] Figure 2 This is a top view of the structure of an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the main structure of an embodiment of the present invention;

[0034] Figure 4This is a three-dimensional structural schematic diagram of the fixed pitch tensioning device in an embodiment of the present invention;

[0035] Figure 5 This is a schematic diagram of the front cross-sectional structure of the fixed pitch tensioning device in an embodiment of the present invention;

[0036] Figure 6 This is an overall workflow diagram of an embodiment of the present invention;

[0037] Figure 7 This is a schematic diagram illustrating the working principle of the fixed pitch tensioning device in this embodiment of the invention.

[0038] Figure 8 This is a flowchart of the constant winding angle algorithm in an embodiment of the present invention;

[0039] Figure 9 This is a flowchart of the blank length control algorithm in an embodiment of the present invention;

[0040] Figure 10 This is a flowchart of the quality control algorithm in an embodiment of the present invention.

[0041] In the picture:

[0042] 1-Horizontal servo module; 2-Fixed pitch stretching device; 201-Box; 202-Guide pulley mounting bracket; 203-Box cover; 204-Guide pulley; 205-Elastic friction layer; 206-Stretching pressure roller; 207-Fiber optic sensor; 208-Wire cutting side bracket; 209-Wire cutting mounting bracket; 210-Pneumatic shears; 211-Cooling fan; 212-Elastic clamping mechanism; 213-Coupling; 214-Swing bracket; 215-Thrust bearing; 216-Stretching drive motor; 217-Fiber optic amplifier; 218-Counting module; 3-Main spindle servo motor; 4-Vertical motion mechanism; 5-Vision inspection device; 6-Mandrel; 7-Wire guiding mechanism; 8-Wire cutting mechanism; 9-Industrial computer; 10-Workbench; 11-Quality inspection device. Detailed Implementation

[0043] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0044] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0045] like Figures 1-5As shown, the present invention provides a three-axis metal-rubber blank winding device with online detection and closed-loop control, which solves the problems of the winding angle being easily affected by the change of blank radius, the difficulty in maintaining the tangency between the guide wire direction and the blank surface during the existing metal-rubber blank winding process, the difficulty in online closed-loop control of blank length and quality, and the insufficient stability of metal spiral coil stretching and conveying. This improves the consistency, stability and automation of the metal-rubber blank winding process.

[0046] The device includes a workbench 10 with an industrial computer 9 mounted on top. A spindle servo motor 3 is mounted on the workbench 10 to clamp and drive the mandrel 6 to rotate. A fixed-pitch stretching device 2, driven left and right by a horizontal servo module 1, is mounted in front of the spindle servo motor 3. The fixed-pitch stretching device 2 stretches the metal spiral coil to a preset pitch and conveys it from front to back to the wire guiding mechanism 7. A wire cutting mechanism 8 is also mounted on the fixed-pitch stretching device 2. A vision inspection device 5 is mounted above the mandrel 6. The horizontal servo module 1 drives the fixed-pitch stretching device 2 along the axis of the mandrel 6. The winding process involves reciprocating motion (i.e., left and right movement); a fixed-pitch stretching device 2 is mounted on a horizontal servo module 1 to stretch the metal spiral coil to a preset pitch state and convey the stretched metal spiral coil to the wire guiding mechanism 7 at a set conveying speed; a vision inspection device 5 is used to acquire contour images of the metal rubber blank during the winding process and feed back the real-time radius and actual length of the blank to the industrial computer 9; the wire guiding mechanism 7 is used to guide the stretched metal spiral coil to the mandrel 6 according to a preset winding angle; and the wire cutting mechanism 8 is used to cut the metal spiral coil when the blank winding is completed or the system stops. It should be noted that this part of the structure is identical to the content of the intelligent winding device and method for metal rubber blanks with visual closed-loop feedback in publication number CN121927974A, and will not be repeated here.

[0047] The specific improvements to this device include a vertical motion mechanism 4 and a quality detection device 11. The vertical motion mechanism 4 drives the spindle servo motor 3 and the mandrel 6 to move vertically up and down. The vertical motion mechanism 4 is electrically connected to the industrial computer 9. By driving the spindle servo motor 3 and the mandrel 6 to perform position compensation according to the change of the blank radius, the metal spiral coil output by the wire guide mechanism 7 can continuously remain tangent to the outer surface of the blank, thereby reducing the impact of the wire entry angle and tension fluctuations on the winding angle from a physical structure perspective. The quality detection device 11 is installed on the metal spiral coil conveying path of the fixed pitch stretching device 2. It is used to detect the number of units of the metal spiral coil when it is conveyed at a set conveying speed and to feed the detection results back to the industrial computer 9.

[0048] In this embodiment, to achieve constant pitch stretching and stable conveying of the metal spiral coil, the constant pitch stretching device 2 includes a box body 201 with a box cover 203 on the top, and two sets of stretching rollers 206 spaced apart along the conveying direction of the metal spiral coil and located above the box cover 203. Each set of stretching rollers 206 includes a fixed roller 2061 distributed on the left and right and a floating roller 2062. The axes of the fixed roller and the floating roller are both vertical. The floating roller can open or close relative to the fixed roller in the left and right direction. The constant pitch stretching device 2 is provided with an elastic clamping mechanism 212 for applying clamping force to the floating roller. Under the elastic clamping action of the elastic clamping mechanism 212, the floating roller can form an adaptive clamping gap with the change of the diameter of the metal spiral coil, so that the floating roller and the fixed roller form an elastic clamping of the metal spiral coil. An elastic friction layer 205 is provided in the groove on the circumferential side of the stretching roller 206 to improve the friction between the roller and the metal spiral coil during the stretching process, thereby improving the stretching and conveying stability of the metal spiral coil.

[0049] In this embodiment, the elastic clamping mechanism 212 can be, for example, an existing spring plunger. The spring plunger is installed on the side of the housing 201, and its telescopic end abuts against the swing bracket 214 to apply an elastic preload force toward the fixed pressure roller to the swing bracket 214.

[0050] In this embodiment, the two sets of tension rollers 206 are a low-speed roller group and a high-speed roller group distributed in front and behind, respectively. The low-speed roller group and the high-speed roller group run at different angular velocities, and the angular velocity of the low-speed roller group is less than that of the high-speed roller group.

[0051] In this embodiment, in each set of tension rollers, the fixed roller and the floating roller are driven to rotate by tension drive motors 216 installed in the housing 201. The output shaft of the tension drive motor 216 is connected to the corresponding roller through a coupling 213. Specifically, the tension drive motor 216 corresponding to the fixed roller is fixedly installed on the housing cover 203 or the housing 201, and the tension drive motor 216 corresponding to the floating roller is installed on a swing bracket 214. The swing bracket 214 is located inside the housing 201, and one end of the top of the swing bracket 214 is rotatably installed on the housing cover 203 through a thrust bearing 215, so that the floating roller 2062 can open or close relative to the fixed roller 2061. The elastic clamping mechanism 212 is connected to the swing bracket 214 and is used to apply clamping force to the swing bracket 214, so that the swing bracket 214 drives the floating roller to press against the fixed roller, thereby forming an elastic clamp between the floating roller and the fixed roller on the metal spiral coil. With the cooperation of the floating pressure roller, the elastic clamping mechanism 212 and the elastic friction layer 205, the fixed pitch stretching device 2 can adapt to metal spiral coils of different diameters and reduce the situation where the metal spiral coil is flattened due to the rigid gap of the pressure roller being too small, or is separated from the stretching pressure roller 206 due to the gap of the pressure roller being too large.

[0052] In this embodiment, a guide pulley mounting bracket 202 is provided at the middle of the front end of the fixed pitch stretching device 2, and a rotatable guide pulley 204 is mounted on the guide pulley mounting bracket 202; the guide pulley 204 is used to guide and limit the metal spiral coil before it enters the stretching pressure roller 206, so as to improve the stability of the metal spiral coil when it enters the stretching area.

[0053] In this embodiment, a cooling fan 211 may also be provided on the side of the housing 201 to dissipate heat from the stretching drive motor 216 and the interior of the housing 201.

[0054] In this embodiment, the wire guide mechanism 7 is located on the discharge side of the fixed-pitch stretching device 2. It guides the stretched metal spiral coil for output and oscillates according to the control parameters issued by the industrial computer 9, so that the metal spiral coil is laid on the mandrel 6 or the surface of the metal-rubber blank at a preset winding angle. Furthermore, the wire guide mechanism 7 can adopt an oscillating guide structure or other guide structures that can achieve the same guiding function.

[0055] In this embodiment, the quality detection device 11 includes an optical fiber sensor 207, an optical fiber amplifier 217, and a counting module 218. The optical fiber sensor 207 is positioned on the conveying path of the two metal spiral coils of the fixed-pitch stretching device and is located before the stretched metal spiral coils enter the winding area of ​​the mandrel 6. The optical fiber amplifier 217 is connected to the optical fiber sensor 207 and is used to receive the detection signal fed back by the optical fiber sensor 207, and convert the light intensity change generated when the metal spiral coil passes through the position of the quality detection device 11 into a switching pulse signal according to a preset detection threshold. The counting module 218 is connected to the optical fiber amplifier 217 and is used to effectively count the switching pulse signals and feed back the effective counting results to the industrial computer 6. The industrial computer 6 calculates the number of metal spiral coil units entering the mandrel winding area based on the effective counting results fed back by the counting module, and further calculates the real-time quality of the blank.

[0056] In this embodiment, to achieve automatic wire cutting control after the blank quality reaches a preset value, a wire cutting mechanism 8 is also provided on the discharge side of the fixed pitch stretching device 2. The wire cutting mechanism 8 includes a wire cutting side bracket 208, a wire cutting mounting bracket 209, and a pneumatic scissor 210. The wire cutting side bracket 208 is installed on both sides of the fixed pitch stretching device 2, and the wire cutting mounting bracket 209 is located between the upper ends of the two wire cutting side brackets 208. The pneumatic scissor 210 is installed on the wire cutting mounting bracket 209 and is used to cut the stretched metal spiral coil.

[0057] In this embodiment, the vision inspection device 5 is used to acquire contour images of the metal-rubber blank during the winding process and transmit the image data to the industrial computer 9. The industrial computer 9 extracts the blank contour region based on image processing algorithms and obtains geometric parameters such as the real-time radius of the blank, the actual length of the blank, and the end contour changes.

[0058] In this embodiment, the industrial computer 9 is used to perform parameter calculations, motion control, and closed-loop feedback adjustment for the entire machine's operation. Specifically, during normal winding, the industrial computer 9 controls the fixed-pitch stretching device 2 to output the metal spiral coil at a set conveying speed, ensuring that the metal spiral coil remains in a stable conveying state when it passes the detection position of the quality detection device 11. Simultaneously, based on the real-time radius of the blank obtained by the vision inspection device 5, the industrial computer 9 controls the spindle servo motor 3 to dynamically adjust its speed to maintain a preset winding angle between the metal spiral coil laying direction and the axis of the mandrel 6.

[0059] In this embodiment, the industrial computer 9 is also used to control the vertical motion mechanism 4 to drive the spindle servo motor 3 and the mandrel 6 to perform tangential position compensation in the vertical direction according to the real-time radius change of the blank, so that the metal spiral coil output by the wire guide mechanism 7 is kept tangential to the outer surface of the metal rubber blank; at the same time, the industrial computer 9 corrects the effective winding stroke of the horizontal servo module 1 in the next cycle according to the actual length of the blank obtained by the vision inspection device 5, and calculates the real-time quality of the blank according to the number of metal spiral coils obtained by the quality inspection device 11. When the real-time quality of the blank reaches the preset value, the wire cutting mechanism 8 is controlled to cut the metal spiral coil.

[0060] In this embodiment, the horizontal servo module 1 is an actuator capable of converting servo control signals into linear motion. It includes a servo motor, a driver, a lead screw transmission mechanism, and a guide rail assembly. The servo motor operates according to set motion parameters under the control of the driver and drives the slide to move linearly along the guide rail direction through the lead screw transmission mechanism. The fixed pitch tensioning device 2 is mounted on the slide of the horizontal servo module 1 to realize the reciprocating movement of the fixed pitch tensioning device 2 along the axial direction of the mandrel 6.

[0061] In this embodiment, the online detection closed-loop control method for winding triaxial metal-rubber blanks includes the following steps:

[0062] Step 1: Input the target blank pitch, preset winding angle, target blank length, and target blank mass into the industrial computer 9;

[0063] Step 2: Install the metal spiral coil into the fixed pitch stretching device 2. The two sets of stretching rollers 206 in the fixed pitch stretching device 2 clamp the metal spiral coil through the fixed roller 2061 and the floating roller 2062, and the floating roller and the fixed roller form an elastic clamping of the metal spiral coil through the elastic clamping mechanism 212.

[0064] Step 3: The system executes the initialization program. The horizontal servo module 1, the vertical motion mechanism 4, and the wire guide mechanism 7 return to their initial positions. The two sets of tension rollers of the fixed pitch tensioning device 2 run at different speeds. The metal spiral coil is stretched to the preset pitch state by the speed difference between the two sets of tension rollers 206, and then output to the surface of the mandrel 6 through the wire guide mechanism 7.

[0065] Step 4: After initialization, the industrial computer 9 issues a normal winding command. The fixed pitch stretching device 2, the main spindle servo motor 3, the horizontal servo module 1, the vertical motion mechanism 4, and the wire guide mechanism 7 work together to lay the metal spiral coil on the mandrel 6 or the surface of the metal rubber blank at the preset winding angle.

[0066] Step 5: During the normal winding process, the fixed pitch stretching device 2 outputs the metal spiral coil at a set conveying speed, so that the metal spiral coil passes through the detection position of the quality detection device 11 in a stable conveying state; the vision detection device collects the outline image of the metal rubber blank and feeds back the real-time radius and actual length of the blank to the industrial computer.

[0067] Step six: The industrial computer 9 dynamically adjusts the speed of the spindle servo motor 3 according to the real-time radius of the blank to maintain the preset winding angle between the metal spiral coil laying direction and the axis of the mandrel 6; at the same time, the industrial computer 9 controls the vertical motion mechanism 4 to perform vertical tangential compensation according to the real-time radius of the blank, so that the metal spiral coil output by the wire guide mechanism 7 remains tangent to the outer surface of the metal rubber blank.

[0068] Step 7: Industrial computer 9 corrects the effective winding stroke of horizontal servo module 1 for the next cycle based on the error between the actual length of the blank and the target blank length. When horizontal servo module 1 enters the reversal transition section, fixed pitch stretching device 2 pauses stretching and wire output, horizontal servo module 1 performs reversal geometric compensation, wire guide mechanism 7 switches the guiding direction, and vertical motion mechanism 4 performs reversal auxiliary compensation.

[0069] Step 8: The quality inspection device 11 detects the number of metal spiral coil units entering the winding area of ​​the mandrel 6 through the fiber optic sensor 207, fiber optic amplifier 217 and counting module 218. The industrial computer calculates the real-time quality of the blank based on the number of units.

[0070] Step 9: When the real-time quality of the blank reaches the target blank quality, the industrial computer 9 controls the spindle servo motor 3, the horizontal servo module 1, the fixed pitch stretching device 2, and the vertical motion mechanism 4 to stop running, and drives the wire cutting mechanism 8 to cut the metal spiral coil.

[0071] Step 10: When the system enters the paused operation state, the industrial computer 9 records the current operating parameters, real-time geometric parameters of the blank, and current counting data of the spindle servo motor 3, horizontal servo module 1, fixed pitch stretching device 2, vertical motion mechanism 4, vision inspection device 5, and quality inspection device 11, so that the system can continue to run later; when the system receives a stop control command, the industrial computer 9 controls the whole machine to stop running, and after the wire cutting is completed, the system enters the standby state, waiting for the next winding initialization.

[0072] In this embodiment, the correction of the effective winding stroke of the horizontal servo module 1 in the next cycle includes the following steps: (1) After the current formal winding segment ends, the visual inspection device 5 obtains the actual length of the metal rubber blank; the industrial computer 9 compares the actual length with the target blank length to obtain the length error; when the length error is within the preset allowable range, the industrial computer keeps the effective winding stroke of the next cycle unchanged; when the actual length is less than the target blank length, the industrial computer 9 increases the effective winding stroke of the next cycle; when the actual length is greater than the target blank length, the industrial computer decreases the effective winding stroke of the next cycle; (2) When the horizontal servo module 1 enters the reversing transition segment, the fixed pitch stretching device 2 suspends stretching and wire output, the horizontal servo module 1 performs reversing geometric compensation, the wire guide mechanism 7 switches the guiding direction, and the vertical motion mechanism 4 performs reversing auxiliary compensation; the horizontal compensation stroke of the reversing transition segment is not included in the effective winding length of the metal rubber blank.

[0073] In this embodiment, the specific implementation process of fixed-pitch stretching control during the winding of the metal-rubber blank is as follows: When the fixed-pitch stretching device 2 is working, the industrial computer 9 sends speed commands to the high-speed and low-speed roller groups according to the target pitch parameters, causing the two sets of stretching rollers 206 to run at different angular velocities. The metal spiral coil passes sequentially through the clamping area between the two sets of stretching rollers 206, and is stretched from a dense state to a preset pitch state under the action of the speed difference between the two sets of stretching rollers 206. Its working principle is as follows: Figure 7 As shown. During the stretching process, since the floating pressure roller can undergo a slight displacement relative to the fixed pressure roller, it can form an adaptive clamping gap according to the change of the diameter of the metal spiral coil, thereby adapting to metal spiral coils of different diameters; at the same time, the elastic clamping mechanism 212 can provide a stable clamping force for the metal spiral coil, reducing the situation where large-diameter spiral coils are rigidly flattened and small-diameter spiral coils are dislodged from the stretching pressure roller 206 due to excessive pressure roller gap.

[0074] Furthermore, the ratio of the pitch of the stretched metal spiral coil to the speed of the high-speed pressure roller group and the low-speed pressure roller group can be expressed by the following calibration mapping relationship:

[0075]

[0076] In the formula: The pitch after stretching; The pitch compensation coefficient is obtained through experimental calibration. The initial pitch of the spiral coil. High-speed pressure roller angular velocity, The low-speed pressure wheel angular velocity; according to this formula, it can be seen that by adjusting... and The speed ratio allows for control of the tension pitch of the metal spiral coil.

[0077] During actual stretching, if the effective normal clamping force F provided by the elastic clamping mechanism 212 to the pressure roller is insufficient, it will lead to insufficient friction between the pressure roller and the metal spiral coil, causing local slippage and affecting the stability of the stretching pitch. The effective normal clamping force provided by the elastic clamping mechanism can meet the following requirements:

[0078]

[0079] In the formula: F is the effective normal clamping force provided by the elastic clamping mechanism, N is the equivalent axial tensile stiffness of the spiral coil, P is the pitch after tension, and P0 is the initial pitch of the spiral coil. It is the equivalent coefficient of friction between the elastic friction layer 205 and the metal spiral coil.

[0080] In this embodiment, as Figure 8 As shown, the specific implementation process for achieving a constant winding angle during the winding of the metal-rubber blank is as follows: During the winding process of the metal-rubber blank, the actual laying state of the metal spiral coil on the blank surface is mainly affected by the feed speed of the horizontal servo module 1, the rotation speed of the spindle servo motor 3, and the vertical compensation position of the vertical motion mechanism 4. Specifically, the rotation speed of the spindle servo motor 3 is used to adjust the tangential linear velocity of the blank surface to maintain the preset winding angle; the vertical motion mechanism 4 is used to compensate for the change in the tangential position of the blank's outer surface caused by the increase in the blank radius, ensuring that the metal spiral coil output by the wire guide mechanism 7 always remains tangential to the outer surface of the blank, thereby avoiding tension fluctuations caused by an increase in the wire entry angle and thus preventing damage to the actual winding angle.

[0081] The system uses a vision inspection device 5 to acquire real-time contour images of the metal-rubber blank during the winding process. An industrial computer 9 extracts the blank contour region based on an image segmentation algorithm and obtains the real-time radius set of the blank's axial position. Let the blank be wound to the [number missing] [number missing] [section missing]. When layered, its continuous radius distribution function along the motion direction of horizontal servo module 1 is: Its mathematical expression is:

[0082]

[0083] In the formula: These are the current position coordinates of the horizontal servo module 1; For the first Layer blank in position The real-time radius at that location; These are the curve fitting coefficients.

[0084] To maintain a constant winding angle of the metal spiral coil on the blank surface, let the feed speed of the horizontal servo module 1 be... The spindle servo motor 3 is in position The angular velocity at is The tangential linear velocity of the blank surface is Then we have:

[0085]

[0086] If the preset winding angle is And the wrapping angle Defined as the angle between the direction of the metal spiral coil laying and the axis of mandrel 6, its geometric relationship satisfies:

[0087]

[0088] Will Substituting into the above formula, we can obtain the position of the spindle servo motor 3. The target angular velocity at that location should satisfy:

[0089]

[0090] In the formula: Preset winding angle; This refers to the axial feed speed of the horizontal servo module 1. The spindle servo motor 3 is in position The target angular velocity at that location; This represents the real-time radius of the blank at the current position.

[0091] Meanwhile, as the number of winding layers increases, the radius of the metal-rubber blank gradually increases. Since the exit height of the guide wire mechanism 7 remains fixed during winding, if the center position of the mandrel 6 remains unchanged, the tangential position between the metal spiral coil and the outer surface of the blank will change as the blank radius increases. This causes an entry angle between the metal spiral coil at the exit of the guide wire mechanism 7 and the blank surface, resulting in spiral coil tension fluctuations and disrupting the actual winding angle. To solve this problem, the industrial computer 9, based on the real-time blank radius obtained by the vision inspection device 5, controls the vertical motion mechanism 4 to drive the spindle servo motor 3 and the mandrel 6 to perform position compensation in the vertical direction, ensuring that the metal spiral coil exit direction remains tangential to the blank surface.

[0092] Let the height of the exit center of the guide wire mechanism 7 be... The center of spindle 6 is at the current position. The vertical position of the target is , No. Layer blank in position The real-time radius at that location is The installation compensation amount is The metal spiral coil output by the wire guide mechanism 7 should always remain tangent to the outer surface of the blank, satisfying the mapping relationship:

[0093]

[0094] Therefore, we can conclude that:

[0095]

[0096] In the formula: The height of the exit center of the guide wire mechanism 7; The vertical position of the center target of mandrel 6; The real-time radius of the blank at the current position; This is a comprehensive compensation amount for the outlet center of the wire guide mechanism 7, the radius of the metal spiral coil, and installation errors.

[0097] In actual control, to simplify the control calculation of the vertical motion mechanism 4, a relative displacement compensation method can be adopted. Let the initial radius of the blank be... The initial vertical position of the center of spindle 6 is And if the downward movement of the vertical motion mechanism 4 is defined as the positive direction, then the target compensation displacement of the vertical motion mechanism 4 is:

[0098]

[0099] The target vertical positions of the corresponding spindle servo motor 3 and spindle 6 are:

[0100]

[0101] In the formula: This is the compensation displacement of the vertical motion mechanism 4; The target vertical position of the spindle servo motor 3 and the spindle 6; The initial radius of the blank during initialization; This represents the real-time radius of the blank at the current position.

[0102] When the vertical motion mechanism 4 uses a lead screw module transmission, let the lead screw lead be... The number of control pulses corresponding to each revolution of the motor is The number of compensation pulses corresponding to the vertical motion mechanism 4 is:

[0103]

[0104] In the formula: The number of compensation pulses for the vertical motion mechanism 4; The lead of the lead screw for the vertical motion mechanism 4; This represents the number of control pulses corresponding to each revolution of the motor.

[0105] The industrial computer 9 issues position control commands to the vertical motion mechanism 4 based on the aforementioned compensation amount, causing the center of the mandrel 6 to move downward synchronously as the radius of the blank increases, thereby ensuring that the metal spiral coil at the wire exit of the wire guide mechanism 7 remains tangent to the surface of the metal-rubber blank. Through the dynamic correction of the spindle servo motor 3's speed and the tangent position compensation of the vertical motion mechanism 4, a constant winding angle can be achieved, and the consistency of blank winding can be improved.

[0106] In this embodiment, as Figure 9 As shown, the specific implementation process of achieving length closed-loop and horizontal module reversal compensation during the metal-rubber blank winding process is as follows: During the metal-rubber blank winding process, the movement process of the horizontal servo module 1 includes a reversal transition section and a formal winding section. The reversal transition section is used to cooperate with the wire guide mechanism 7 to complete the swing direction switching and wire feed direction adjustment before and after the horizontal servo module 1 changes its movement direction; the formal winding section is used to lay the metal spiral coil after fixed pitch stretching on the mandrel 6 or the surface of the metal-rubber blank according to the preset winding angle.

[0107] Let the preset winding angle be θ, and the distance between the center line of the mandrel 6 and the swing reference position of the guide wire mechanism 7 be... The horizontal compensation travel corresponding to the reversing transition section is:

[0108]

[0109] In the formula: For commutation geometry compensation stroke; θ is the distance between the center line of the mandrel 6 and the swing reference position of the guide wire mechanism 7; θ is the preset winding angle between the metal spiral coil laying direction and the axis of the mandrel 6.

[0110] After system initialization, the horizontal servo module 1 returns to its origin position, which corresponds to the left edge of the metal-rubber blank. The fixed-pitch stretching device 2 first pre-stretches the metal spiral coil to a certain distance. When winding begins, the fixed-pitch stretching device 2 pauses stretching the filament, and the horizontal servo module 1 performs a reversing geometric compensation stroke along the first direction. Simultaneously, the wire guide mechanism 7 swings to a guide position corresponding to the preset winding angle. Subsequently, the fixed pitch tensioning device 2, the spindle servo motor 3, the horizontal servo module 1, and the wire guide mechanism 7 work together, and the system enters the formal winding stage.

[0111] In the formal winding segment, the effective winding stroke of the horizontal servo module 1 is used to determine the actual forming length of the blank. Let the target blank length input by the user be... The effective winding stroke corresponding to the kth winding cycle is The effective winding stroke and the reversing geometric compensation stroke are then... Independent of each other, commutation geometry compensation travel The effective winding length of the blank is not included.

[0112] After the industrial camera of the vision inspection device acquires an image of the metal rubber blank, the industrial computer 9 extracts the blank contour region based on the image segmentation algorithm, and extracts the pixel coordinates of the left end boundary of the blank along the axis of the mandrel 6. and the right boundary pixel coordinates Let the axial pixel equivalent be... The actual length of the blank obtained from the k-th detection is... for:

[0113]

[0114] In the formula: The actual length of the blank obtained from the kth detection; and These are the pixel coordinates of the left and right edges of the blank, respectively. It is the axial pixel equivalent.

[0115] Let the target blank length be The length error obtained from the kth detection is... for:

[0116]

[0117] Industrial Computer 9 based on length error The effective winding stroke for the next cycle is corrected. Let the length compensation coefficient be... Then the effective winding distance in the next cycle for:

[0118]

[0119] In the formula: This represents the effective winding stroke of the current cycle horizontal servo module 1; The effective winding stroke after correction for the next cycle; This is the length compensation coefficient.

[0120] when When the actual length of the current blank is less than the target blank length, the industrial computer 9 controls the horizontal servo module 1 to appropriately increase the effective winding stroke for the next cycle; when When the actual length of the current blank is greater than the target blank length, the industrial computer 9 controls the horizontal servo module 1 to appropriately reduce the effective winding stroke of the next cycle.

[0121] To avoid frequent corrections by the horizontal servo module 1 when the length error is small, the system can set an allowable length error threshold. When the following conditions are met: | |≤ At that time, the industrial computer 9 maintains the current effective winding stroke. Unchanged; when: | |> At that time, the industrial computer 9 based on the length error Effective winding stroke for the next cycle Make corrections.

[0122] Furthermore, to address the metal spiral pullback phenomenon caused by the smooth surface of the mandrel 6 during the first layer winding process, the system can be configured with a first layer pullback compensation amount. This ensures that the initial effective winding stroke of the first layer of formal winding segment satisfies:

[0123]

[0124] In the formula: This is the initial effective winding stroke of the first layer of formal winding segment; This is the first-layer pullback compensation amount obtained through experimental calibration. By setting the first-layer pullback compensation amount, the phenomenon of the actual blank length being too short during the first-layer winding caused by the smooth surface of the mandrel 6, insufficient adhesion of the metal spiral coil, and the reversing traction of the horizontal servo module 1 can be reduced.

[0125] When the horizontal servo module 1 reaches the end of the blank and needs to reverse direction, the fixed pitch stretching device 2 pauses the stretching and wire feeding, and the horizontal servo module 1 performs the reversing geometric compensation stroke. The wire guide mechanism 7 swings to the other guide position, and then the system enters the reverse formal winding section. During the reversal process, the vertical motion mechanism 4 can drive the main spindle servo motor 3 and the mandrel 6 to rise relative to the normal tangential position by a preset reversal auxiliary compensation amount. This increases the coating contact between the metal spiral coil and the end of the blank, reducing slippage, loosening, and end accumulation during the reversing process.

[0126] Let the vertical position of the center target of mandrel 6 during the formal winding stage be... And it is stipulated that the downward movement of the vertical motion mechanism 4 is the positive direction, then the vertical auxiliary position during the reversing stage is... for:

[0127]

[0128] In the formula: The target position of the vertical motion mechanism 4 during the reversing phase; To maintain the vertical position of the mandrel 6 center target required for tangency during the formal winding stage; This is the commutation auxiliary compensation amount.

[0129] When the vision inspection device 5 detects that the actual length of the blank is greater than the target blank length, or detects that the two ends of the blank have an outward expansion trend, the industrial computer 9 reduces the effective winding stroke for the next cycle. And combined with the real-time radius distribution function of the blank The target angular velocity of the spindle servo motor 3 is synchronously corrected to reduce the excessive winding tendency in the large radius area at the end and suppress the accumulation of metal spiral coils at both ends of the blank.

[0130] Through the aforementioned length closed-loop control, commutation geometry compensation, and vertical auxiliary compensation, the system can separate the commutation action of the horizontal servo module 1 from the effective winding length control of the blank, and correct the effective winding stroke layer by layer according to the actual length of the blank obtained by visual detection, thereby improving the length consistency and end laying stability of the metal rubber blank.

[0131] In this embodiment, as Figure 10 The following is a detailed implementation process for detecting the quality of a metal-rubber blank during the winding process:

[0132] Let the real-time detection signal fed back by the fiber optic sensor 207 be... The detection threshold set by the fiber optic amplifier is The switching signal output by the fiber optic amplifier is In one implementation, the switching signal can be represented as:

[0133]

[0134] In the formula: This is the real-time detection signal fed back by the fiber optic sensor 207; The detection threshold set for the fiber optic amplifier; This is a switching signal output by the fiber optic amplifier. Depending on the detection method of the fiber optic sensor 207, the switching signal can also be set to low-level trigger or high-low level toggle trigger.

[0135] The counting module receives the switching pulse signal output from the fiber optic amplifier and counts the rising or falling edges of the switching pulse signal to obtain the cumulative number of valid pulses. To reduce the impact of ambient light changes, equipment vibration, and slight oscillations of the metal spiral coil on the detection results, the counting module can filter, de-jitter, determine the minimum pulse width, or determine the adjacent pulse interval of the pulse signal output from the fiber optic amplifier, and only use pulse signals that meet preset conditions as valid counting signals.

[0136] The number of valid pulses accumulated by the design module is: The conversion factor for unit spiral count is: The number of unit spiral coils currently entering the winding area of ​​mandrel 6 It can be represented as:

[0137]

[0138] In the formula: This represents the current number of spiral coils per unit. The number of valid pulses accumulated by the counting module; This is the conversion factor for counting. When one valid pulse corresponds to one unit of spiral coil, When the fiber optic sensor 207 generates multiple valid pulses for one spiral unit, or multiple spiral units correspond to one valid pulse, It can be obtained through experimental calibration.

[0139] Let the density of the metal wire be... The diameter of the metal spiral wire is The diameter of the metal spiral coil is The theoretical mass of a single unit spiral coil is... It can be represented as:

[0140]

[0141] In the formula: The theoretical mass of a single unit spiral coil; The density of the metal wire; The diameter of the metal spiral wire; The diameter of the metal spiral coil is given. Considering errors in wire diameter, spiral coil diameter, tensile deformation, and detection counting, a quality correction coefficient can be introduced into the system. The current real-time quality of the blank. It can be represented as:

[0142]

[0143] Will Substituting into the above equation, we get:

[0144]

[0145] In the formula: This represents the current real-time quality of the raw material. This is a mass correction factor, which can be calibrated based on actual weighing results.

[0146] When the detection is stable and one valid pulse corresponds to one unit spiral coil, it can be taken as follows: When the deviation between the theoretical calculation value and the actual weighing value is small, the value can be taken as... At this point, the real-time mass of the blank and the number of unit spiral coils can be simplified as follows:

[0147]

[0148] In the formula: For the real-time quality of the blank; The number of unit spiral coils wound onto mandrel 6.

[0149] Furthermore, let the target blank quality input by the user be... The permissible quality error is When the following conditions are met: or At that time, the industrial computer 9 determines that the current blank quality has reached the preset requirements and sends a stop winding command to the spindle servo motor 3, the horizontal servo module 1, the fixed pitch stretching device 2 and the vertical motion mechanism 4, while controlling the wire cutting mechanism 8 to cut the metal spiral coil.

[0150] In actual control, since there is a certain distance between the detection position of the fiber optic sensor 207 and the actual winding point of the wire cutting mechanism 8 or the mandrel 6, the system can be set to provide margin compensation counting. This is used to compensate for the number of metal spiral coils that continue to enter the winding area between the detection position and the wire-cutting position. Let the target unit spiral coil number be... The target effective pulse count value is ,but:

[0151]

[0152] In the formula: The effective pulse count value that triggers the stop winding and wire cutting actions; The number of unit spiral coils corresponding to the target blank quality; This is a count for margin compensation.

[0153] When the counting module obtains the cumulative number of valid pulses Achieve target effective pulse count value At that time, the industrial computer 9 issues a stop winding command in advance and controls the wire cutting mechanism 8 to perform the wire cutting action, so as to reduce the impact of the distance lag between the detection position and the wire cutting position on the final quality of the blank.

[0154] In this way, the quality detection device 11 can convert the continuous conveying process of the metal spiral coil into countable pulse signals, and the industrial computer 9 can calculate the blank quality in real time. When the real-time quality of the blank reaches the set value, the system automatically stops winding and performs wire cutting action, thereby realizing online detection, closed-loop control and automated quantitative preparation of blank quality.

[0155] The advantages of this invention are:

[0156] (1) The present invention achieves winding angle correction by dynamically adjusting the spindle servo motor speed while maintaining the stable conveying speed and quality detection speed of the metal spiral coil. This is beneficial to balance winding angle control and stable detection of the unit quantity of metal spiral coil.

[0157] (2) The present invention compensates for the tangential position of the spindle servo motor and the mandrel by means of a vertical motion mechanism, so that the direction of the metal spiral winding is tangential to the outer surface of the blank, which can reduce the wire entry angle and the resulting tension fluctuation, and improve the consistency of blank laying.

[0158] (3) The present invention obtains the actual length of the blank through a visual inspection device and corrects the effective winding stroke of the next cycle according to the length error, thereby realizing closed-loop control of the blank length, which is beneficial to reduce the influence of factors such as reversal pull-back and end accumulation on the consistency of blank length.

[0159] (4) The present invention uses fiber optic sensors, fiber optic amplifiers and counting modules to detect the number of metal spiral coils entering the mandrel winding area, and uses an industrial computer to calculate the real-time quality of the blank, thereby realizing online detection, quantitative control and automatic wire cutting linkage of blank quality;

[0160] (5) In the fixed pitch stretching device of the present invention, the combination of floating pressure roller, elastic clamping mechanism and elastic friction layer enables the fixed pitch stretching device to adapt to metal spiral coils of different diameters and reduces the situation of the spiral coil being flattened, slipping or coming off during the stretching and conveying process, thereby improving the stability of stretching and conveying.

[0161] If this invention discloses or relates to components or structural parts that are fixedly connected to each other, then, unless otherwise stated, a fixed connection can be understood as: a fixed connection that can be detached (e.g., using bolts or screws), or a fixed connection that cannot be detached (e.g., riveting, welding). Of course, a fixed connection can also be replaced by an integral structure (e.g., manufactured in one piece using a casting process) (except where it is obviously impossible to use an integral molding process).

[0162] In addition, unless otherwise stated, the terms used in any of the technical solutions disclosed in this invention to indicate positional relationships or shapes include states or shapes that are similar to, close to, or approximate with those states or shapes.

[0163] Any component provided by this invention can be assembled from multiple individual components or can be a single component manufactured by a one-piece molding process.

[0164] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. A three-axis metal-rubber blank winding device with online detection and closed-loop control, comprising a worktable equipped with an industrial computer, a main spindle servo motor for clamping and driving the mandrel to rotate on the worktable, a fixed-pitch stretching device driven by a horizontal servo module to move left and right on the front side of the main spindle servo motor, the fixed-pitch stretching device stretching the metal spiral coil to a preset pitch state and conveying it from front to back to a wire guiding mechanism, and a vision inspection device above the mandrel, characterized in that: It also includes a vertical motion mechanism and a quality detection device. The vertical motion mechanism drives the spindle servo motor and the mandrel to move vertically up and down. The vertical motion mechanism is electrically connected to the industrial computer. The quality detection device is set on the metal spiral coil conveying path of the fixed pitch stretching device. It is used to detect the unit quantity of the metal spiral coil when it is conveyed at a set conveying speed, and to feed the detection result back to the industrial computer.

2. The triaxial metal-rubber blank winding device with online detection and closed-loop control according to claim 1, characterized in that: The fixed-pitch stretching device includes a housing with a top cover, and two sets of stretching rollers spaced apart along the metal spiral winding conveying direction and located above the cover. Each set of stretching rollers includes a fixed roller and a floating roller distributed on the left and right. The floating roller can open or close relative to the fixed roller. The fixed-pitch stretching device is provided with an elastic clamping mechanism for applying clamping force to the floating roller. Under the elastic clamping action of the elastic clamping mechanism, the floating roller can form an adaptive clamping gap with the change of the metal spiral winding diameter, so that the floating roller and the fixed roller form an elastic clamping of the metal spiral winding. An elastic friction layer is provided in the groove of the stretching roller.

3. The triaxial metal-rubber blank winding device with online detection and closed-loop control according to claim 2, characterized in that: The two sets of tension rollers are a low-speed roller group and a high-speed roller group distributed at the front and rear, respectively, and the low-speed roller group and the high-speed roller group operate at different angular velocities. In each set of tension rollers, the fixed roller and the floating roller are driven to rotate by tension drive motors installed in the box. The tension drive motor corresponding to the fixed roller is fixedly installed on the box cover or box body, and the tension drive motor corresponding to the floating roller is installed on a swing bracket. The swing bracket is rotatably installed on the box cover, so that the floating roller can open or close relative to the fixed roller. The elastic pressing mechanism is connected to the swing bracket to apply a pressing force to the swing bracket, so that the swing bracket drives the floating roller to press towards the fixed roller.

4. The triaxial metal-rubber blank winding device with online detection and closed-loop control according to claim 1, characterized in that: The quality inspection device includes an optical fiber sensor, an optical fiber amplifier, and a counting module. The optical fiber sensor is positioned on the metal spiral coil conveying path of the fixed-pitch stretching device, before the stretched metal spiral coil enters the mandrel winding area. The optical fiber amplifier is connected to the optical fiber sensor and receives the detection signal fed back by the optical fiber sensor. Based on a preset detection threshold, it converts the light intensity change generated when the metal spiral coil passes the position of the quality inspection device into a switching pulse signal. The counting module is connected to the optical fiber amplifier and effectively counts the switching pulse signals, feeding back the effective counting results to an industrial computer. The industrial computer calculates the number of metal spiral coil units entering the mandrel winding area based on the effective counting results fed back by the counting module and further calculates the real-time quality of the blank.

5. The triaxial metal-rubber blank winding device with online detection and closed-loop control according to claim 1, characterized in that: The discharge side of the fixed-pitch stretching device is also equipped with a wire-cutting mechanism. The wire-cutting mechanism includes a wire-cutting side bracket, a wire-cutting mounting bracket, and a pneumatic shear. The wire-cutting side bracket is installed on both sides of the fixed-pitch stretching device, and the wire-cutting mounting bracket is located between the upper ends of the two wire-cutting side brackets. The pneumatic shear is installed on the wire-cutting mounting bracket and is used to cut the stretched metal spiral coil. The industrial computer is also used to correct the effective winding stroke of the horizontal servo module in the next cycle based on the actual length of the blank obtained by the vision inspection device, and to calculate the real-time quality of the blank based on the number of metal spiral coils obtained by the quality inspection device. When the real-time quality of the blank reaches the preset value, the wire-cutting mechanism is controlled to cut the metal spiral coil.

6. The triaxial metal-rubber blank winding device with online detection and closed-loop control according to claim 1, characterized in that: The vision inspection device is used to acquire the contour image of the metal rubber blank during the winding process and feed back the real-time radius and actual length of the blank to the industrial computer. The industrial computer controls the vertical motion mechanism to drive the main spindle servo motor and the mandrel to move in the vertical direction according to the real-time radius change of the blank, so as to perform tangential position compensation and keep the metal spiral coil output by the wire guide mechanism tangential to the outer surface of the metal rubber blank.

7. A method for online detection and closed-loop control of triaxial metal-rubber blank winding, characterized in that: The device includes a triaxial metal-rubber blank winding apparatus employing online detection and closed-loop control as described in any one of claims 1-6, comprising the following steps: Step 1: Input the target blank pitch, preset winding angle, target blank length, and target blank mass into the industrial computer; Step 2: The fixed pitch stretching device stretches the metal spiral coil at a fixed pitch by the speed difference between two sets of stretching rollers, and during the normal winding process, the metal spiral coil passes through the detection position of the quality detection device at a set conveying speed. Step 3: The vision inspection device acquires the outline image of the metal rubber blank and feeds back the real-time radius and actual length of the blank to the industrial computer. Step four: While maintaining a stable conveying speed of the metal spiral coil and a stable detection speed at the quality inspection device, the industrial computer dynamically adjusts the rotation speed of the spindle servo motor based on the real-time radius of the blank to maintain the preset winding angle. Step 5: The industrial computer controls the vertical motion mechanism to perform vertical tangential compensation based on the real-time radius of the blank, so that the metal spiral coil output by the wire guide mechanism remains tangential to the outer surface of the metal rubber blank. Step 6: The industrial computer corrects the effective winding stroke of the horizontal servo module for the next cycle based on the error between the actual length of the blank and the target blank length. Step 7: The quality inspection device detects the number of metal spiral coil units entering the mandrel winding area through fiber optic sensors, fiber optic amplifiers and counting modules. The industrial computer calculates the real-time quality of the blank based on the number of units. Step 8: When the real-time quality of the blank reaches the target blank quality, the industrial computer controls the whole machine to stop winding and drives the wire cutting mechanism to cut the metal spiral coil.

8. The online detection and closed-loop control method for winding triaxial metal-rubber blanks according to claim 7, characterized in that: In step six, the correction of the effective winding stroke of the horizontal servo module in the next cycle includes the following steps: (1) After the current formal winding segment ends, the vision inspection device obtains the actual length of the metal rubber blank; the industrial computer compares the actual length with the target blank length to obtain the length error; when the length error is within the preset allowable range, the industrial computer keeps the effective winding stroke of the next cycle unchanged; when the actual length is less than the target blank length, the industrial computer increases the effective winding stroke of the next cycle; when the actual length is greater than the target blank length, the industrial computer decreases the effective winding stroke of the next cycle; (2) When the horizontal servo module enters the reversing transition segment, the fixed pitch stretching device pauses the stretching of the wire, the horizontal servo module performs reversing geometric compensation, the wire guide mechanism switches the guiding direction, and the vertical motion mechanism performs reversing auxiliary compensation; the horizontal compensation stroke of the reversing transition segment is not included in the effective winding length of the metal rubber blank.

9. The online detection and closed-loop control method for winding triaxial metal-rubber blanks according to claim 7, characterized in that: In step two, the ratio of the pitch of the stretched metal spiral coil to the speed of the high-speed pressure roller group and the low-speed pressure roller group can be expressed by the following calibration mapping relationship: In the formula: The pitch after stretching; The pitch compensation coefficient is obtained through experimental calibration. The initial pitch of the spiral coil. High-speed pressure roller angular velocity, The low-speed pressure wheel angular velocity; according to this formula, it can be seen that by adjusting... and The speed ratio allows for control of the tension pitch of the metal spiral coil; The effective normal clamping force provided by the elastic clamping mechanism can meet the following requirements: In the formula: F is the effective normal clamping force provided by the elastic clamping mechanism, N is the equivalent axial tensile stiffness of the spiral coil, P is the pitch after tension, and P0 is the initial pitch of the spiral coil. It is the equivalent coefficient of friction between the elastic friction layer 205 and the metal spiral coil.

10. The online detection and closed-loop control method for winding triaxial metal-rubber blanks according to claim 7, characterized in that: The specific implementation process of achieving length closed loop and horizontal module reversal compensation during the winding of metal rubber blanks is as follows: During the winding of metal rubber blanks, the movement process of the horizontal servo module includes a reversal transition section and a formal winding section; the reversal transition section is used to cooperate with the wire guide mechanism to complete the switching of swing direction and the adjustment of wire entry direction before and after the horizontal servo module changes the direction of movement; the formal winding section is used to lay the metal spiral coil after fixed pitch stretching on the mandrel or the surface of the metal rubber blank according to the preset winding angle.

Images