A method and system for controlling the take-up of enameled wire using a slanted plane composite take-up reel.

Abstract

This invention relates to the field of enameled wire take-up technology, and discloses a control method and system for enameled wire take-up using a slanted plane composite take-up reel. The control method includes the following steps: S1: Obtain the real-time winding diameter of the slanted plane composite take-up reel; S2: Obtain the real-time taper wire placement displacement deviation of the slanted plane composite take-up reel based on the real-time winding diameter; S3: Dynamically correct the wire placement parameters based on the taper wire placement displacement deviation; S4: Drive the wire placement motor to place the wire according to the corrected wire placement parameters, and cyclically execute S1-S3 to form a closed-loop control. This invention, through the control method, can improve problems such as uneven wire placement, taper winding offset, wire overlap, and loose wire in traditional enameled wire take-up equipment, effectively improving the quality of enameled wire winding and forming, enhancing the automation level and production stability of the equipment, and adapting to continuous production operations of various specifications of enameled wire.

Description

Technical Field

[0001] This invention relates to the field of enameled wire take-up technology, and in particular to a method and system for controlling enameled wire take-up using a slanted planar composite take-up reel. Background Technology

[0002] In the production of enameled wire, the take-up process requires the finished enameled wire to be wound evenly and smoothly onto the take-up reel. Traditional double-headed conical reels have conical structures at both ends, resulting in uneven stress on both ends of the wire during winding. This easily leads to problems such as uneven tension at both ends, uneven end faces, and edge collapse, with forming defects being particularly noticeable after winding long lengths. Single-headed conical reels simplify the structure, with a single-sided conical guide, ensuring uniform stress during winding. This optimizes the wire forming foundation from a structural perspective, eliminating forming deviations at both ends. In the take-up process, the accuracy of wire arrangement directly affects the coil winding quality and subsequent processing performance. However, the original wire arrangement uses a mechanical cam or gear linkage mechanism, whose wire trajectory depends on the fixed matching relationship between the geometric symmetry of the reel and the mechanical transmission ratio. This method suffers from problems such as complex structure, difficulty in adjustment, and inability to adapt to different wire diameters and tension changes. When the winding diameter continues to increase during the take-up process, the mechanical linkage cannot dynamically respond to the axial displacement requirements caused by the slope of the conical surface, resulting in the enameled wire stacking or uneven spacing in the conical area. In addition, existing technologies for wire routing control are mostly based on preset stroke or open-loop counting methods, which lack the perception and feedback of real-time winding diameter and cannot achieve highly consistent axial positioning under the guidance of a single-sided conical surface.

[0003] How to design the motion trajectory and control strategy of the wire guide for this asymmetrical structure take-up reel so that the enameled wire can evenly fill the conical and cylindrical areas of the entire take-up reel, while avoiding problems such as uneven wire laying, slippage or interlayer misalignment in the conical area, is a technical problem that urgently needs to be solved. Summary of the Invention

[0004] To address one or more problems existing in the prior art, the present invention provides a method and system for controlling the take-up of enameled wire using a slanted plane composite take-up reel.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] In a first aspect, the present invention provides a method for controlling the take-up of enameled wire using a slanted plane composite take-up reel. The slanted plane composite take-up reel includes a conical region, a cylindrical region, and a disc region arranged coaxially. The smaller end of the conical region is adjacent to one end of the cylindrical region, the larger end of the conical region faces outward, and the other end of the cylindrical region is adjacent to the disc region. The control method includes the following steps:

[0007] S1: Obtain the real-time winding diameter of the inclined plane composite take-up reel;

[0008] S2: Based on the real-time winding diameter, obtain the real-time taper wire laying displacement deviation of the inclined plane composite take-up reel;

[0009] S3: Dynamically correct the wiring parameters based on the tapered wiring displacement deviation;

[0010] The cable routing parameters include the cable reversal point positions P1 and P2. During each layer of winding and rewinding on the inclined plane composite take-up reel, the cable routing device traverses the conical region and the cylindrical region in a single continuous reciprocating stroke between the first reversal point P1 and the second reversal point P2. The total length of this single continuous reciprocating stroke, |P2-P1|, increases from L as the number of take-up layers increases. cyl Gradually expand to L cyl +L cone ; among which, L cone L is the design axial length of the conical region along the cable direction. cyl L is the designed axial length of the cylindrical region along the cable direction. cyl L cone All units are in mm;

[0011] S4: Drive the wiring motor to lay the wires according to the corrected wiring parameters, and execute S1-S3 in a loop to form a closed-loop control.

[0012] In an optional implementation, the specific process of obtaining the real-time winding diameter of the inclined plane composite take-up reel in step S1 includes:

[0013] S11: Real-time acquisition of the take-up motor shaft pulse signal via proximity switch, and statistical analysis of the real-time speed N of the take-up motor;

[0014] S12: Based on the preset constant linear velocity V and the rotational speed N, calculate the real-time winding diameter D of the take-up reel according to the diameter calculation formula, which is: D=(V / (π×N))×1000.

[0015] In the formula: D is in mm; V is in m / min; N is in r / min.

[0016] In an optional implementation, the formula for calculating the tapered cable displacement deviation in step S2 is: ΔS=K×(D-D0),

[0017] In the formula: ΔS is the tapered cable delivery displacement deviation, in mm; K is the tapered proportion coefficient of the tapered surface region of the inclined plane composite take-up disc, K=L cone / (D 大端 -D 小端 ), D 小端 =D0,D 大端 =Diameter at the large end of the conical region, D大端 D 小端 All units are mm; K has no unit; D is the real-time winding diameter, in mm; D0 is the diameter of the initial empty cylindrical region of the inclined plane composite take-up reel, in mm.

[0018] In an optional implementation, in step S3, the calculation formulas for the first reversing point P1 and the second reversing point P2 are: when n=1, P1=P base P2=P base -L cyl ;

[0019] When n>1, P1=P base +ΔS, P2=P base -L cyl ;

[0020] Among them, P base The axial position coordinates at the junction of the cylindrical region and the conical region are determined by the axial installation position of the inclined plane composite take-up reel after it is installed on the take-up spindle, and are a fixed constant during a single take-up process; n is the number of take-up layers; ΔS increases with the number of take-up layers, causing the first reversing point P1 to move from P... base Expanding outwards layer by layer towards the larger end of the cone-shaped region until reaching P. base +L cone The line was successfully retracted.

[0021] In an optional implementation, in step S4, during the closed-loop control, when the cable guide is located within the conical area, the first PID control parameter group is used for position and speed control; when the cable guide is located within the cylindrical area, the control switches to the second PID control parameter group for position and speed control; the proportional coefficient p1, integral coefficient i1, and derivative coefficient d1 of the first PID control parameter group are different from the proportional coefficient p2, integral coefficient i2, and derivative coefficient d2 of the second PID control parameter group.

[0022] In an optional implementation, the taper ratio coefficient K is obtained through an automatic calibration step, which includes:

[0023] S21: In the empty disk state, drive the cable guide to run to the beginning of the conical area and record the current cable guide reference position L0;

[0024] S22: During the winding process, the linear speed V of the enameled wire is kept constant. The preset number of layers n of enameled wire are wound up, and the winding diameter D at this time is recorded. n ;

[0025] S23: The drive cable tray moves to the new starting position L of the conical region after winding n layers of enameled wire. nRecord the axial offset ΔL = L of the cable reference position. n - L0;

[0026] S24: Based on the axial offset ΔL and the change in winding diameter (D) n - D0) Automatically calculate the taper ratio coefficient K = ΔL / (D n - D0), and write this coefficient into the system parameters.

[0027] In an optional implementation, when the wire guide is located within the conical region, the wire guide step distance is set to the first step distance value S1; when the wire guide is located within the cylindrical region, the wire guide step distance is set to the second step distance value S2; wherein, S2=S0, S1=S0 / cosα, S0=c×d0, S0 is the basic wire guide step distance in mm; d0 is the diameter of the enameled wire in mm; c is the overlay coefficient, which takes a value of 0.9-1.2; α is the half-cone angle of the conical region in °.

[0028] Secondly, the present invention provides a wire take-up control system for an oblique plane composite take-up reel, comprising the wire take-up control method for an oblique plane composite take-up reel as described in any of the above embodiments, including:

[0029] The speed detection module includes a proximity switch installed at the position of the take-up motor shaft, which is used to detect the pulse signal of the take-up motor shaft in real time and output the speed signal;

[0030] The winding diameter calculation module is configured in the PLC controller and is electrically connected to the speed detection module. It is used to receive the speed signal and calculate the real-time winding diameter D of the take-up reel.

[0031] The tapered cable displacement deviation calculation module is configured in the PLC controller and is electrically connected to the winding diameter calculation module. It is used to calculate the tapered cable displacement deviation ΔS based on the real-time winding diameter D.

[0032] The wiring parameter correction module, configured within the PLC controller, is electrically connected to the tapered wiring displacement deviation calculation module. It is used to dynamically correct the wiring parameters based on the tapered wiring displacement deviation ΔS. The wiring parameters include the wiring reversal point positions P1 and P2.

[0033] The stepper drive module includes a stepper motor driver and a stepper motor. The stepper motor driver is electrically connected to the cable parameter correction module and is used to receive pulse signals output by the PLC controller. The stepper motor is driven by the stepper motor driver.

[0034] The cable routing execution module includes a ball screw and a cable routing device mounted thereon. The ball screw is connected to the stepper motor for driving the cable routing device to move laterally above the inclined plane composite take-up reel.

[0035] The PLC controller controls the cable guide to traverse the conical region and the cylindrical region in a single continuous reciprocating stroke between the corrected first reversing point P1 and the second reversing point P2 in each layer of reciprocating motion. The total length of the single continuous reciprocating stroke, |P2-P1|, increases from L as the number of take-up layers increases. cyl Gradually expand to L cyl +L cone After each layer of wiring is completed, the PLC controller re-triggers the winding diameter calculation module, the tapered wiring displacement deviation calculation module, and the wiring parameter correction module to perform a new round of calculations, forming a closed-loop control.

[0036] Furthermore, the PLC controller is equipped with a regional differentiation control module, which includes:

[0037] The region identification unit is used to determine whether the cable tray is in the conical region or the cylindrical region based on its current position.

[0038] The PID parameter switching unit is used to switch the PID control parameter group of the cable controller to the pre-stored parameter group corresponding to the current region when a region switch is detected.

[0039] The step size switching unit is used to switch the ribbon cable step size to the step size value corresponding to the current area when a region switch is detected.

[0040] Furthermore, the enameled wire take-up control system of the inclined plane composite take-up reel also includes an automatic calibration module. This automatic calibration module is configured within the PLC controller to perform the following automatic calibration steps: recording the wire routing reference position L0 in an empty reel state, and recording the winding diameter D after winding a preset number of layers n. n And the new position L of the reference position of the cable n Calculate the axial offset ΔL = L n - L0, and according to K = ΔL / (D n - D0) Automatically calculates and updates the taper ratio coefficient K.

[0041] This invention utilizes a collaborative design of a slanted plane composite take-up reel and adaptive wire laying control to ensure that the wire laying trajectory strictly adapts to the single-sided conical guide path, thereby improving the winding uniformity of the enameled wire in the conical region. By dynamically generating the tapered wire laying displacement deviation based on the real-time winding diameter, it overcomes the axial offset caused by the cumulative change in winding diameter. Furthermore, by independently driving the ball screw with a stepper motor, it eliminates the backlash and lag introduced by mechanical linkage, enhancing the consistency of wire laying response.

[0042] Compared with the prior art, the present invention has at least the following beneficial effects:

[0043] Automatic layer-by-layer filling of the conical area: Since the displacement deviation of the tapered wire varies with the winding diameter, the position of the wire reversal point is dynamically adjusted by obtaining the real-time tapered wire displacement deviation through the real-time winding diameter, so that the stroke range of the wire guide gradually increases, and the conical area is automatically filled layer by layer until the entire coil is filled, thereby ensuring that the conical surface is uniformly filled.

[0044] High control stability: In this invention, the cable guide moves continuously between two regions, a conical region and a cylindrical region. The position of the reversal point in the conical region is dynamically corrected in real time, the motion trajectory is predictable, the planning is simple, and the response consistency is better when running at high speed.

[0045] Regional adaptive differentiated control: PID parameters and cable laying step distance can be dynamically switched according to the real-time position of the cable laying device to achieve high-response and fast maneuvering in the conical section and high-precision and stable cable laying in the cylindrical section, taking into account the different control requirements of the two regions. Attached Figure Description

[0046] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0047] Figure 1 This is a schematic diagram of the inclined plane composite take-up reel in an embodiment of the present invention;

[0048] Figure 2 This is a schematic diagram of the enameled wire take-up device with a slanted plane composite take-up reel in an embodiment of the present invention;

[0049] Figure 3 This is a flowchart of the enameled wire take-up control method of the inclined plane composite take-up reel in an embodiment of the present invention.

[0050] In the diagram: 1-Cylindrical region; 2-Conical region; 3-Disc region;

[0051] 4-Stepper motor driver; 5-Stepper motor; 6-Cable guide; 7-Ball screw; 8-Screw nut; 9-Take-up motor; 10-Take-up reel. Detailed Implementation

[0052] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall apply. Reagents or instruments whose manufacturers are not specified are all conventional products that can be purchased commercially.

[0053] In this application, for ease of engineering description, the axial coordinates of the cabling are defined with the mechanical zero point at the junction of the cylindrical and conical regions as the origin, the direction from the junction to the large end of the conical region as the positive direction, and the direction from the junction to the cylindrical region as the negative direction. Under this coordinate system, the conical region is located on the positive half-axis, and the cylindrical region is located on the negative half-axis. The starting position of the cabling foundation (i.e., the axial position coordinates at the junction of the cylindrical and conical regions) is P. base It is a constant, determined by the installation position of the coil. The displacement ΔS towards the larger end of the conical region is represented as a positive increment (i.e., added to ΔS) in the coordinate system.

[0054] Example 1

[0055] This embodiment provides a method for controlling the take-up of enameled wire using a slanted plane composite take-up reel, applied to a slanted plane composite take-up reel with an asymmetric structure. For example... Figure 1 As shown, the inclined plane composite take-up reel includes a conical region, a cylindrical region and a disk region arranged coaxially. The small end of the conical region is adjacent to one end of the cylindrical region, the large end of the conical region faces outward, and the other end of the cylindrical region is adjacent to the disk region.

[0056] like Figure 2 The diagram shown is a schematic of the enameled wire take-up device of the inclined plane composite take-up reel in this embodiment. It is a schematic diagram of an existing device structure, shown here for ease of understanding. It includes a stepper motor driver 4, a stepper motor 5, a wire guide 6, a ball screw 7, a screw nut 8, a take-up motor 9, and a take-up reel 10. The stepper motor 5 is controlled by the stepper motor driver 4. The ball screw 7 is connected to the output shaft of the stepper motor 5. The screw nut 8 is mounted on the ball screw 7 and is connected to the wire guide 6. The take-up motor 9 controls the winding action of the take-up reel 10.

[0057] In this embodiment, a Ф0.50mm enameled wire is selected, a constant linear speed V=100m / min is set, the initial diameter of the empty cylindrical region of the inclined plane composite take-up reel (i.e., the empty reel diameter) D0=100mm, and the diameter at the large end of the conical region (i.e., the full reel diameter) D 大端=180mm. The pre-set taper ratio coefficient K = 0.5 (dimensionless) for the conical surface region of the inclined plane composite take-up reel, and the design axial length L of the conical surface region along the cable laying direction. cone =40mm, the design axial length L of the cylindrical region along the cable direction cyl =240mm, basic cabling step distance S0=0.5mm (S0=c×d0, d0 is the diameter of the enameled wire in mm, in this embodiment d0=0.50mm; c is the overlay coefficient, which is 0.9-1.2, and is selected according to the cabling requirements, in this embodiment c=1.0). Cabling foundation starting position P base The calibration is set to 0mm (based on the mechanical zero point of the cable guide, i.e., the axial position coordinate at the junction of the cylindrical and conical regions is set as P). base The direction from the boundary to the larger end of the cone-shaped region is the positive direction.

[0058] like Figure 3 As shown, the method for controlling the take-up of enameled wire using a slanted plane composite take-up reel includes the following steps:

[0059] S1: Obtain the real-time winding diameter of the inclined plane composite take-up reel.

[0060] A proximity switch (e.g., an inductive proximity switch) is installed at the end of the shaft of the take-up motor. This proximity switch detects the metal teeth on the motor shaft and outputs a pulse signal each time the shaft passes a tooth. In this embodiment, 60 pulses are generated per rotation of the shaft.

[0061] The pulse signal from the proximity switch is connected to the high-speed counter input port of the PLC controller. The PLC controller counts the real-time pulses within each control cycle (set to 50ms in this embodiment) and calculates the real-time speed N of the take-up motor using the following formula:

[0062] N = (Number of pulses / 60) × (60 / Acquisition time)

[0063] For example: if 15 pulses are collected within 50ms, then N = (15 / 60) × (60 / 0.05) = 300 r / min.

[0064] Based on the preset constant linear velocity V=100m / min and the above-mentioned real-time rotational speed N, the real-time winding diameter D of the take-up reel is calculated according to the diameter calculation formula:

[0065] D=(V / (π×N))×1000

[0066] Substituting the above values: D = 100 / (3.1416 × 300) ×1000≈ 106mm, where V / N can be understood as the length of the wire traveled by the winding motor in one revolution at speed N (i.e., the winding circumference). Dividing the circumference by π gives the winding diameter.

[0067] As winding progresses, the diameter of the take-up reel gradually increases, and the rotational speed N gradually decreases. If 10 pulses are collected within 50ms at a certain moment during the winding process, then: N = (10 / 60) × (60 / 0.05) = 200 r / min. At this time, D = 100 / (3.1416 × 200) ≈ 0.159m = 159mm, indicating that the diameter of the take-up reel has increased to approximately 159mm.

[0068] Under constant linear velocity V (m / min) control mode, the length of enameled wire wound up per revolution of the take-up reel is equal to its circumference C (mm) = πD (mm). The reel speed Nr (r / min) and the take-up motor speed Nm (r / min) satisfy the relationship Nr = Nm / i (i is the transmission ratio), and the length of wire wound per unit time is the linear velocity V (m / min), therefore:

[0069] V ×1000= π × D × Nr = π × D × Nm / i

[0070] The transformation yields:

[0071] D = V × 1000 × i / (π × Nm)

[0072] In this embodiment, the take-up motor is directly connected to the take-up reel (i = 1), so it is simplified to:

[0073] D = (V / (π × N)) × 1000

[0074] In the formula, D is the real-time winding diameter (mm), V is the preset constant linear speed (m / min), N is the real-time rotational speed of the take-up motor (r / min), and π is taken as 3.1416. This formula converts rotational speed measurement into diameter calculation, allowing the current winding diameter of the take-up reel to be obtained in real time without the need for an additional diameter measuring sensor, providing a reference parameter for the subsequent calculation of the reversing point position.

[0075] To ensure calculation accuracy, in this embodiment, the D value is recalculated once every control cycle (50ms) and subjected to a first-order low-pass filter to reduce the interference of pulse counting jitter on the calculation results. The filter coefficient is 0.2.

[0076] S2: Based on the real-time winding diameter, obtain the real-time taper displacement deviation of the inclined plane composite take-up reel.

[0077] Based on the real-time winding diameter D obtained in step S1, the PLC controller calculates the tapered cable displacement deviation ΔS according to the following formula:

[0078] ΔS = K × (D - D0)

[0079] In the formula, ΔS is the tapered cable delivery displacement deviation, in mm; K is the tapered proportional coefficient of the inclined plane composite take-up reel, K=L cone / (D 大端 -D 小端 ), D 小端 =D0,D 大端 =Diameter at the large end of the conical region, D 大端 D 小端 All units are mm; K has no unit; D is the real-time winding diameter, in mm; D0 is the diameter of the initial empty cylindrical region of the inclined plane composite take-up reel, in mm.

[0080] The values ​​of the parameters in the formula are: K=0.5, D0=100mm.

[0081] Taking an empty disk with D=D0=100mm as an example: ΔS = 0.5× (100 - 100) = 0mm, no taper compensation is needed at this time.

[0082] When D increases to 120mm: ΔS = 0.5 × (120-100) = 10mm.

[0083] Similarly, when D increases to 180mm (full plate diameter): ΔS = 0.5 × (180-100) = 40mm.

[0084] It can be seen that ΔS increases linearly with the winding diameter D, and the compensation amount also increases linearly.

[0085] S3: Dynamically correct the wiring parameters based on the tapered wiring displacement deviation.

[0086] The wiring parameters include the wiring reversal point positions P1 and P2. Based on the tapered wiring displacement deviation ΔS obtained in step S2, the system dynamically corrects the wiring reversal point positions.

[0087] Those skilled in the art will understand that the take-up process of a take-up reel includes the reel rotating while the cable guide (such as enameled wire) reciprocates along the axial direction of the take-up reel. The reversing point is the starting and ending position of the cable guide during its reciprocating motion. The cable guide reciprocates between these two positions. In this application, the first reversing point P1 is the starting position, and the second reversing point P2 is the ending position. The cable guide reciprocates between the first reversing point P1 and the second reversing point P2 during each layer of winding and take-up on the inclined plane composite take-up reel. In this application, after the inclined plane composite take-up reel is installed, the first reversing point P1 is set as the starting position P of the cable guide base. base Let the second reversal point P2 be the location of the boundary between the cylindrical region and the disk region, i.e., P base -L cyl After the cable laying begins, the cable laying device starts from the first reversing point P1, passes through the cylindrical area, reaches the second reversing point P2, and then runs in the opposite direction. It then runs back to the first reversing point P1 and runs in the opposite direction again, repeating this process between the first reversing point P1 and the second reversing point P2. During the cable take-up process, based on the tapered cable laying displacement deviation ΔS obtained in step S2, the system dynamically corrects the position of the cable laying reversing point.

[0088] The formulas for calculating the first reversal point P1 (which can be understood as the reversal point on the conical region side) and the second reversal point P2 (which can be understood as the reversal point on the cylindrical region side) are as follows:

[0089] When n=1, P1=P base P2=P base -L cyl ;

[0090] When n>1, P1=P base +ΔS, P2=P base -L cyl ;

[0091] Where P base =0mm, L cone =40mm, L cyl =240mm.

[0092] n is the number of receiving layers. When n=1, P1=P base =0mm, P2=P base -L cyl =0-240=-240mm; When n>1, taking ΔS=10mm (D=120mm) as an example:

[0093] P1 = 0 + 10 = 10mm

[0094] P2 = 0 -240 = -240mm

[0095] The cable guide moves between P1 (10mm) and P2 (-240mm), with a total stroke length of 250mm = |P2-P1| = ΔS + L cyl .

[0096] In this embodiment:

[0097] When the empty reel is winding up one layer: the cable guide travel range = 0 to (0-240) = 0 to -240mm, with a range length of 240mm;

[0098] When taking in several layers of wire (e.g., ΔS=10mm): the wire guide travel range is 10mm to -240mm, and the range length is 250mm;

[0099] When the cable is fully wound up (e.g., ΔS=40mm): the cable guide travel range is 40mm to -240mm, with a range length of 280mm;

[0100] It can be seen that after the tapered cable displacement deviation compensation, the stroke range gradually moves towards the larger end of the tapered area, and the total stroke length of a single layer cable gradually increases from 240mm to 280mm.

[0101] In each layer of winding and reciprocating motion, the cable guide travels from the first reversing point P1 to the second reversing point P2 in a single continuous reciprocating stroke, and then returns to the first reversing point P1, passing through the conical area and the cylindrical area in sequence.

[0102] During the first layer of cabling, the cabling device travels axially from the junction of the cylindrical and conical regions to the other end of the cylindrical region. The first reversal point P1 is P. base There is no need to expand outwards towards the larger end of the conical region; furthermore, starting the wiring from the boundary between the cylindrical region and the conical region ensures that during the first layer of wiring, the first reversing point does not move towards the larger end of the conical region, but only during the second layer of wiring does it begin to move towards the larger end of the conical region (P). base To P base The initial wiring with +ΔS can eliminate the step effect caused by the geometric abrupt change at the junction of the cylindrical and conical regions, alleviate radial compression damage at the junction, and provide buffer space for mechanical and control errors in the wiring stroke, ensuring that the disc shape is flat and tight.

[0103] In this application, the number of take-up layers is described in terms of the number of take-up layers in a cylindrical region.

[0104] S4: Drive the wiring motor to lay the wires according to the corrected wiring parameters, and execute S1-S3 in a loop to form a closed-loop control.

[0105] According to the wiring parameters corrected in step S3, the PLC controller outputs a corresponding pulse signal to the stepper motor driver, which drives the stepper motor to drive the wiring device on the ball screw to perform the wiring action.

[0106] The cable guide starts from the first reversing point P1, and travels through the conical and cylindrical regions in a single continuous reciprocating stroke to reach the second reversing point P2. Then, it reverses from the second reversing point P2 back to the first reversing point P1, completing one cable guide reciprocating stroke. During the reciprocating stroke, the corresponding first reversing point P1 gradually advances axially towards the larger end of the conical region, increasing the tapered cable guide displacement deviation distance.

[0107] After completing one layer of wiring, the program returns to step S1, re-acquires the take-up motor speed, recalculates the real-time winding diameter D, recalculates the tapered wiring displacement deviation ΔS, and corrects the wiring parameters. It then drives the wiring motor again to perform the next layer of wiring. This process repeats continuously, forming a real-time closed-loop control until take-up is complete. In this embodiment, when the first commutation point P1 reaches P... base +L cone The winding cycle stops when the target weight for winding is reached. In another embodiment, a target weight for winding can be set, and the winding cycle stops when the system detects that the target weight has been reached. In yet another embodiment, the full diameter of the reel can be set, and the winding cycle stops when the system detects that the full diameter has been reached.

[0108] Example 2

[0109] Based on Example 1, this embodiment further introduces a regionally differentiated PID control strategy in the closed-loop control of step S4.

[0110] Specifically, two sets of PID control parameters are preset in the PLC controller:

[0111] Table 1 PID Control Parameters

[0112] proportionality coefficient P <![CDATA[p 1 = 1.2]]> <![CDATA[p2 = 1.8 <!-- 7 -->]]> Integral coefficient I <![CDATA[i 1 = 0.03]]> <![CDATA[i2 = 0.06]]> Differential coefficient D <![CDATA[d 1 = 0.2]]> <![CDATA[d2 = 0.4]]>

[0113] Region identification is determined by the current axial position coordinates of the cable tray:

[0114] When the current position coordinate of the cable tray is located at (P) base , P base +L cone When within the interval (i.e., moving L from P1 towards the larger end), cone Based on the distance, it is determined that the area is within the cone region;

[0115] When the current position coordinates of the cable tray are located at [P] base -L cyl , P base When the value is within the specified interval, it is determined to be in a cylindrical region.

[0116] When the cable guide moves from the conical region to the cylindrical region (or vice versa), the PLC controller automatically performs PID parameter switching operations within a single control cycle. Each time a switch occurs, the current integral term is first cleared to zero (to prevent integral saturation), and then the PID parameter set for the target region is loaded.

[0117] In this embodiment, a smaller scaling factor and integral factor are used in the conical region to help suppress cable jitter caused by geometric changes in the conical surface; a slightly larger scaling factor and integral factor are used in the cylindrical region to improve cable speed response and tracking accuracy.

[0118] Example 3

[0119] The difference between this embodiment and Embodiment 1 is that it provides an automatic calibration step for the taper ratio coefficient K, which is performed when the equipment is put into use for the first time or when the coil specification is changed.

[0120] S21: Record the empty disk reference position.

[0121] In the empty reel state (no enameled wire on the reel, cylindrical area diameter D0 = 100mm), the drive wire guide moves to the beginning of the conical area (i.e., the junction of the cylindrical area and the conical area of ​​the take-up reel). When the photoelectric sensor installed at the end of the ball screw detects the wire guide obstruction signal, the PLC automatically records the current wire guide reference position L0. In this embodiment, the wire guide reference position L0 is the starting position of the wire guide before it starts wire guiding (i.e., the beginning of the conical area), that is, when wire guiding begins, the wire guide starts from this position and moves along the axial direction of the take-up reel, L0 = 0mm.

[0122] S22: Preset number of layers for winding.

[0123] Set a constant linear speed V = 100 m / min and begin winding the enameled wire. Stop winding when the preset number of layers n = 50 is reached. At this point, the PLC controller uses a proximity switch to collect the winding motor speed and calculates the current winding diameter D. n In this embodiment, D n =150mm.

[0124] S23: Record the position of the entire disk.

[0125] The PLC controller drives the cable tray to a new position L at the beginning of the conical area after the number of take-up layers n=50. n The photoelectric sensor automatically detects data, and the PLC controller records the data. n In this embodiment, L n =25mm. Calculate the axial offset: ΔL = L n -L0 = 25 -0 = 25mm.

[0126] During the take-up process, the cable guide starts from the cable guide reference position L0 and moves axially along the take-up reel. It first passes through the cylindrical region, then reaches the boundary between the cylindrical and disc regions. It then reverses direction and returns to the cable guide reference position L0. Next, it continues axially towards the larger end of the conical region until the diameter of the conical region equals the real-time winding diameter. From this point, it reverses direction again, passing through the conical and cylindrical regions sequentially until it reaches the boundary between the cylindrical and disc regions. This process is repeated to ensure cable routing within the conical region. The aforementioned "axial position where the diameter of the conical region equals the real-time winding diameter" is the new starting position L of the conical region. n In this embodiment, the real-time winding diameter is the diameter when the number of take-up layers is 50, at which point D n =150mm, new position L at the beginning of the conical region n This refers to the axial position where the diameter of the conical region is equal to 150mm. The new starting position L of the conical region. n The difference ΔL between the cable guide position and the reference position L0 is the axial offset of the cable guide.

[0127] S24: Calculate the taper ratio coefficient.

[0128] Based on the axial offset ΔL and the change in winding diameter (D) n - D0) Calculate the taper ratio coefficient K: K = ΔL / (D n - D0) = 25 / (150-100) = 25 / 50 = 0.5.

[0129] The PLC controller automatically writes K=0.5 into the system parameter storage area for use as a fixed parameter in subsequent normal production.

[0130] Once the automatic calibration is complete, the equipment can enter the normal closed-loop control production mode.

[0131] Example 4

[0132] Based on Example 1, this embodiment further modifies the cable routing step distance dynamically according to the area where the cable routing device is located during the cable routing control process.

[0133] Specifically, the following cable spacing parameters are preset:

[0134] The basic wiring pitch S0 = 0.5mm (1 times the wire diameter of 0.50mm, i.e., the overlay coefficient c = 1).

[0135] The step distance S1 in the conical area is S0 / cosα = 0.5 / cos45° = 0.7mm (in this embodiment, the half-cone angle α is 45°. The half-cone angle can be designed according to actual needs. For example, it can be any angle value between 30-60°, or it can be designed to meet the winding requirements of the coil).

[0136] The step distance in the cylindrical region is S2 = S0 = 0.5mm.

[0137] The cable guide switches the step distance periodically throughout the entire reciprocating stroke.

[0138] Taking a complete reciprocating stroke as an example: the cable tray moves from P1 (P base Starting from point P, the step distance is 0.5mm for each turn within the cylindrical area. After traveling 480 steps (480 × 0.5 = 240mm) axially, it reaches point P. base -L cyl At (P2); after changing direction, continue moving in the cylindrical area, with a step distance of 0.5mm per turn, until reaching P. base Then it enters the conical region, where it travels 0.7mm per turn, advancing axially to P. base +ΔS turns back, continuing to traverse the conical area with a step size of 0.7mm, returning to P. base A complete cycle is completed at this point.

[0139] By using a larger step size S1 in the conical region, the actual spacing between two adjacent loops of wire along the normal direction of the conical surface in the conical region corresponds to the wiring spacing in the cylindrical region, thus achieving precise wiring with equal spacing in both the conical and cylindrical regions. This compensates for the axial spatial distribution differences caused by the conical geometry, resulting in a more uniform and denser arrangement of enameled wires in the conical region.

[0140] Those skilled in the art will know that the cable guide step distance refers to the axial distance moved by the cable guide (cable guide pin) each time it completes one axial movement during the cable routing process.

[0141] Example 5

[0142] This embodiment provides a wire take-up control system for an oblique plane composite take-up reel, the system including the following components:

[0143] (a) Inclined plane composite take-up reel

[0144] The inclined plane composite take-up reel has an asymmetrical structure, with a conical region on one side and a cylindrical region on the other. The smaller end of the conical region is adjacent to the cylindrical region, while the larger end of the conical region faces outward. The other end of the cylindrical region is adjacent to the disk region.

[0145] In this embodiment, the designed axial length L of the conical surface region of the inclined plane composite take-up disc along the cable laying direction is...cone =40mm, the design axial length L of the cylindrical region along the cable direction cyl =240mm, the initial empty cylindrical region diameter of the inclined plane composite take-up reel (i.e., empty reel diameter) D0=100mm, the diameter at the large end of the conical region (i.e., full reel diameter) D 大端 =180mm. The taper ratio coefficient K=0.5 for the conical surface area of ​​the inclined plane composite take-up disc.

[0146] (ii) Speed ​​detection module

[0147] This includes an inductive proximity switch (model: Omron E2E-X3D1-N) installed at the end of the take-up motor shaft. This switch detects the metal teeth on the shaft, generating 60 pulse signals per shaft rotation and outputting an NPN type pulse signal. The proximity switch has a response frequency of 5kHz, meeting the pulse acquisition requirements within the take-up motor's speed range (100~3000 r / min).

[0148] (iii) PLC controller (with built-in winding diameter calculation module, tapered cable displacement deviation calculation module, and cable parameter correction module)

[0149] The system uses a Mitsubishi FX5U series PLC controller, equipped with a high-speed counter module. The PLC controller receives pulse signals from the proximity switch via the high-speed counter port, and its built-in functional modules perform the following calculations:

[0150] The winding diameter calculation module calculates the real-time winding motor speed N (sampling period 50ms) and the real-time winding diameter D according to the formula D = (V / (π×N))×1000.

[0151] Tapered cable displacement deviation calculation module: Calculate the tapered cable displacement deviation ΔS according to the formula ΔS = K×(D-D0).

[0152] Cable parameter correction module: According to the formula, when n=1, P1=P base P2=P base -L cyl When n>1, P1=P base +ΔS, P2=P base -L cyl The positions of the first commutation point P1 and the second commutation point P2 are corrected, and a pulse signal is output to the stepper motor driver. n is the number of take-up layers.

[0153] In this embodiment, the starting position P of the cabling base base The calibration is set to 0mm (based on the mechanical zero point of the cable guide, i.e., the position at the junction of the cylindrical area and the conical area is set as P). base The direction from the boundary to the larger end of the cone-shaped region is the positive direction.

[0154] (iv) Stepper drive module

[0155] This includes stepper motor drivers and stepper motors.

[0156] The stepper motor driver uses the Leadshine DM542 model, which receives pulse + direction signals output from the PLC controller. The driver is set to 16 microsteps, with each pulse corresponding to a 0.1125° rotation of the stepper motor. Combined with a lead screw of 5mm, the axial displacement of the cable guide corresponding to each pulse is 5×0.1125 / 360≈0.00156mm, meeting the cable guide accuracy requirement of 0.01mm.

[0157] The stepper motor selected is the Leadshine 57HS22 two-phase stepper motor with a step angle of 1.8° and a holding torque of 2.2 N·m, which is sufficient to drive the cabling to overcome the axial load when the conical cabling is laid.

[0158] (v) Cable routing execution module

[0159] Includes a ball screw and a cable guide (cable guide pin) mounted on it.

[0160] The ball screw adopts the HIWIN KK6005 linear ball screw module, with a screw lead of 5mm, an effective stroke of 400mm, and a positioning accuracy of ±0.02mm. A cable guide is installed on the ball screw nut seat, driven by a stepper motor through a flexible coupling. Driven by the ball screw, the cable guide moves laterally above the inclined plane composite take-up reel, realizing the cable guiding action.

[0161] (vi) Human-Machine Interface (HMI)

[0162] A Weintek MT6071iP touchscreen is used, connected to the PLC controller via RS485 communication, for inputting and displaying system parameters such as line speed, empty take-up reel diameter, full take-up reel diameter, take-up reel taper ratio coefficient, take-up reel cone surface length, take-up reel cylinder length, enameled wire diameter, basic cable laying step distance, and cable laying foundation starting position. The take-up reel cone surface length is the designed axial length L of the take-up reel cone surface area along the cable laying direction. cone The length of the take-up reel cylinder is the designed axial length L of the cylindrical area of ​​the take-up reel along the cable laying direction. cyl The starting position of the cabling base is the axial position coordinate P at the junction of the cylindrical region and the conical region. base The take-up reels mentioned above are all inclined plane composite take-up reels.

[0163] System workflow:

[0164] Step 1: Power on and initialize; the PLC controller loads system parameters.

[0165] Step 2: Start the take-up motor and increase it to the set linear speed V=100m / min.

[0166] Step 3: The proximity switch in the speed detection module collects the motor speed pulses in real time, and the PLC controller calculates the real-time winding diameter D and the corresponding number of take-up layers every 50ms.

[0167] Step 4: The PLC controller calculates ΔS based on D. When n=1, P1=P base P2=P base -L cyl ;

[0168] When n>1, P1=P base +ΔS, P2=P base -L cyl Correct the reversal point, where n is the number of receiving layers.

[0169] Step 5: The PLC controller controls the cable arranger to start from P1, travel in a single continuous reciprocating stroke through a portion of the conical and cylindrical areas to P2, then reverses direction and returns to P1, completing one reciprocating cable arrangement cycle. The total length of the cable arrangement stroke gradually increases, from L... cyl Increase to L cyl +L cone .

[0170] Step 6: After completing each layer of cabling, return to Step 3 and repeat the process until the take-up reel reaches its full diameter D. 大端 =180mm, winding complete, automatic stop.

[0171] Example 6

[0172] This embodiment is basically the same as embodiment 5, except that: the proximity switch is a magnetoelectric proximity switch (Hall element), installed at the end of the take-up motor shaft, and detects the magnet installed on the shaft. Each rotation of the shaft generates one pulse signal, and the PLC calculates the real-time rotational speed N by measuring the time interval between two adjacent pulses.

[0173] The rotational speed calculation formula is revised to: N = 60 / T, where T is the time interval between two adjacent pulses (in seconds).

[0174] In this embodiment, the time interval measurement accuracy is 0.1ms, and the corresponding rotation speed measurement range is 1-10000r / min, which can meet the rotation speed measurement requirements of the winding process.

[0175] In this embodiment, the PLC controller is equipped with a regional differentiation control module, which includes three functional units: a regional identification unit, a PID parameter switching unit, and a step size switching unit. The regional identification unit determines whether the cable guide is in a conical or cylindrical region by comparing the current position coordinates of the cable guide with the preset region boundary. When the regional identification unit detects a regional change, the PID parameter switching unit switches the PID control parameter set of the cable guide controller to a pre-stored parameter set corresponding to the current region. When the regional identification unit detects a regional change, the step size switching unit switches the cable guide step size to a step size value corresponding to the current region.

[0176] By using smaller PID parameters and a larger step size in the conical region, wiring jitter in the conical region is effectively suppressed, compensating for the axial spatial distribution differences caused by the conical geometry. Conversely, by using larger PID parameters and a relatively smaller step size in the cylindrical region, wiring response speed and efficiency are improved. The parameters for the two regions are optimized independently without interference.

[0177] The remaining structure and control methods are the same as in Example 5.

[0178] Example 7

[0179] This embodiment is basically the same as Embodiment 5, except that a reducer with a reduction ratio of i=10 is installed between the take-up motor and the reel. Therefore, the calculation formula for the real-time winding diameter (mm) in step S1 is corrected to: D = (V × i / (π × N)) × 1000

[0180] Where i=10, N is the speed of the take-up motor (r / min) (acquired by an encoder), and V is the constant linear velocity (m / min).

[0181] This embodiment also includes an automatic calibration module, which is configured in the PLC controller and is executed when the equipment is put into use for the first time, when the reel specification is changed, or when the reel model is changed.

[0182] Before calibration, install the inclined plane composite take-up reel to be calibrated (empty reel state) on the take-up spindle, ensuring it is properly installed and secure. Access the "Automatic Calibration" interface via HMI, and set the calibration parameters: preset number of layers n = 50 layers, take-up speed V = 100m / min, empty take-up reel diameter D0 = 100mm (provided from the reel drawing or actual measurement), confirm the cable guide is in the non-limited state, and click the "Start Calibration" button.

[0183] The PLC controller drives the cable tray to move slowly towards the larger end of the cone (speed ≤ 50 mm / s), while simultaneously reading the motor drive current value in real time through the stepper motor driver.

[0184] When the cable guide reaches the starting position of the cable laying in an empty reel, the motor load torque increases, and the drive current rises. When the PLC controller detects that the current value exceeds the preset threshold (in this embodiment, it is set to 1.5 times the rated current of the motor, i.e., 3.75A), it determines that the cable guide has reached the starting end of the cable laying on the take-up reel, and the PLC immediately stops driving and records the current absolute position L0.

[0185] In this embodiment, L0 = 0mm (based on the mechanical zero point of the cable guide rail).

[0186] The PLC controller starts the take-up motor to begin winding the enameled wire at a constant linear speed of V=100m / min.

[0187] During the winding process, the winding diameter calculation module calculates the current winding diameter in real time (updating every 50ms). When the number of winding layers reaches the preset number n=50 layers, the PLC controller automatically stops winding.

[0188] At this time, the winding diameter calculation module records the current winding diameter D. n In this embodiment, D n = 150mm.

[0189] The PLC controller drives the cable tray to move slowly towards the larger end of the cone (speed ≤ 50 mm / s), and the motor drive current value is read in real time through the stepper motor driver.

[0190] When the cable guide comes into contact with the starting end of the conical region after 50 layers of winding (i.e., the cable cover layer is in the conical region, where the diameter of the conical region is D), n When the motor load torque increases, the drive current rises. When the PLC controller detects that the current value exceeds the preset threshold, it determines that the cable guide has reached the new starting position after winding n layers, immediately stops the drive, and records the current absolute position L. n .

[0191] In this embodiment, L n = 25mm.

[0192] The PLC controller automatically calculates the axial offset: ΔL = L n - L0 = 25 - 0 = 25mm.

[0193] The PLC controller uses the axial offset ΔL and the change in winding diameter (D) as the basis for its operation. n - D0) Automatically calculate the taper ratio coefficient K:

[0194] K = ΔL / (D n - D0) = 25 / (150 - 100) = 25 / 50 = 0.5

[0195] The PLC controller automatically writes K=0.5 into the system's non-volatile memory and updates the K value parameter in the tapered cable displacement deviation calculation module.

[0196] The remaining structure and control methods are the same as in Example 5.

[0197] The enameled wire take-up control method and system using the inclined plane composite take-up reel of this invention achieves better wire laying quality indicators, with end face height difference ≤0.05mm, conical surface filling rate ≥99.4%, improved wire overlap and gap conditions, significantly enhanced winding consistency, and reduced product scrap rate by more than 90%. This invention achieves automatic adaptive wire laying without manual intervention, improving equipment automation level and production stability, and is suitable for continuous production of enameled wires of various specifications.

[0198] It should be noted that the above description is only 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 principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for controlling the take-up of enameled wire using a slanted plane composite take-up reel, wherein the slanted plane composite take-up reel comprises a conical region, a cylindrical region, and a disc region coaxially arranged, the small end of the conical region is adjacent to one end of the cylindrical region, the large end of the conical region faces outward, and the other end of the cylindrical region is adjacent to the disc region, characterized in that... Includes the following steps: S1: Obtain the real-time winding diameter of the inclined plane composite take-up reel; S2: Based on the real-time winding diameter, obtain the real-time taper wire laying displacement deviation of the inclined plane composite take-up reel; S3: Dynamically correct the wiring parameters based on the tapered wiring displacement deviation; The cable routing parameters include the cable reversal point positions P1 and P2. During each layer of winding and rewinding on the inclined plane composite take-up reel, the cable routing device traverses the conical region and the cylindrical region in a single continuous reciprocating stroke between the first reversal point P1 and the second reversal point P2. The total length of this single continuous reciprocating stroke, |P2-P1|, increases from L as the number of take-up layers increases. cyl Gradually expand to L cyl +L cone ; among which, L cone L is the design axial length of the conical region along the cable direction. cyl L is the designed axial length of the cylindrical region along the cable direction. cyl L cone All units are in mm; S4: Drive the wiring motor to lay the wires according to the corrected wiring parameters, and execute S1-S3 in a loop to form a closed-loop control.

2. The method for controlling the take-up of enameled wire using a slanted plane composite take-up reel according to claim 1, characterized in that, The specific process of obtaining the real-time winding diameter of the inclined plane composite take-up reel in step S1 includes: S11: Real-time acquisition of the take-up motor shaft pulse signal via proximity switch, and statistical analysis of the real-time speed N of the take-up motor; S12: Based on the preset constant linear velocity V and the rotational speed N, calculate the real-time winding diameter D of the take-up reel according to the diameter calculation formula, which is: D=(V / (π×N))×1000. In the formula: D is in mm; V is in m / min; N is in r / min.

3. The method for controlling the take-up of enameled wire using a slanted plane composite take-up reel according to claim 1 or 2, characterized in that, The formula for calculating the tapered cable displacement deviation in step S2 is: ΔS = K × (D - D0), In the formula: ΔS is the tapered cable delivery displacement deviation, in mm; K is the tapered proportion coefficient of the tapered surface region of the inclined plane composite take-up disc, K=L cone / (D 大端 -D 小端 ), D 小端 =D0,D 大端 =Diameter at the large end of the conical region, D 大端 D 小端 All units are mm; K has no unit; D is the real-time winding diameter, in mm; D0 is the diameter of the initial empty cylindrical region of the inclined plane composite take-up reel, in mm.

4. The method for controlling the take-up of enameled wire using a slanted plane composite take-up reel according to claim 3, characterized in that, In step S3, the calculation formulas for the first reversing point P1 and the second reversing point P2 are: when n=1, P1=P base P2=P base -L cyl ; When n>1, P1=P base +ΔS, P2=P base -L cyl ; Among them, P base The axial position coordinates at the junction of the cylindrical region and the conical region are determined by the axial installation position of the inclined plane composite take-up reel after it is installed on the take-up spindle, and are a fixed constant during a single take-up process; n is the number of take-up layers; ΔS increases with the number of take-up layers, causing the first reversing point P1 to move from P... base Expanding outwards layer by layer towards the larger end of the cone-shaped region until reaching P. base +L cone The line was successfully retracted.

5. The method for controlling the take-up of enameled wire using a slanted plane composite take-up reel according to claim 1, characterized in that, In step S4, during the closed-loop control, when the cable guide is located within the conical area, the first PID control parameter group is used for position and speed control; when the cable guide is located within the cylindrical area, the control switches to the second PID control parameter group for position and speed control; the proportional coefficient p1, integral coefficient i1, and derivative coefficient d1 of the first PID control parameter group are different from the proportional coefficient p2, integral coefficient i2, and derivative coefficient d2 of the second PID control parameter group.

6. The method for controlling the take-up of enameled wire using a slanted plane composite take-up reel according to claim 3, characterized in that, The taper ratio coefficient K is obtained through an automatic calibration step, which includes: S21: In the empty disk state, drive the cable guide to run to the beginning of the conical area and record the current cable guide reference position L0; S22: During the winding process, the linear speed V of the enameled wire is kept constant. The preset number of layers n of enameled wire are wound up, and the winding diameter D at this time is recorded. n ; S23: The drive cable tray moves to the new starting position L of the conical region after winding n layers of enameled wire. n Record the axial offset ΔL = L of the cable reference position. n - L0; S24: Based on the axial offset ΔL and the change in winding diameter (D) n - D0) Automatically calculate the taper ratio coefficient K = ΔL / (D n - D0), and write this coefficient into the system parameters.

7. The method for controlling the take-up of enameled wire using a slanted plane composite take-up reel according to claim 5, characterized in that, When the cable guide is located within the conical area, the cable guide step distance is set to the first step distance value S1; when the cable guide is located within the cylindrical area, the cable guide step distance is set to the second step distance value S2. Wherein, S2=S0, S1=S0 / cosα, S0=c×d0, S0 is the basic wiring pitch in mm; d0 is the diameter of the enameled wire in mm; c is the overlay coefficient, which takes a value of 0.9-1.2; α is the half-cone angle of the conical region in °.

8. A wire take-up control system for an inclined plane composite take-up reel, employing the wire take-up control method for an inclined plane composite take-up reel as described in any one of claims 1-7, characterized in that, include: The speed detection module includes a proximity switch installed at the position of the take-up motor shaft, which is used to detect the pulse signal of the take-up motor shaft in real time and output the speed signal; The winding diameter calculation module is configured in the PLC controller and is electrically connected to the speed detection module. It is used to receive the speed signal and calculate the real-time winding diameter D of the take-up reel. The tapered cable displacement deviation calculation module is configured in the PLC controller and is electrically connected to the winding diameter calculation module. It is used to calculate the tapered cable displacement deviation ΔS based on the real-time winding diameter D. The wiring parameter correction module, configured within the PLC controller, is electrically connected to the tapered wiring displacement deviation calculation module. It is used to dynamically correct the wiring parameters based on the tapered wiring displacement deviation ΔS. The wiring parameters include the wiring reversal point positions P1 and P2. The stepper drive module includes a stepper motor driver and a stepper motor. The stepper motor driver is electrically connected to the cable parameter correction module and is used to receive pulse signals output by the PLC controller. The stepper motor is driven by the stepper motor driver. The cable routing execution module includes a ball screw and a cable routing device mounted thereon. The ball screw is connected to the stepper motor for driving the cable routing device to move laterally above the inclined plane composite take-up reel. The PLC controller controls the cable guide to traverse the conical region and the cylindrical region in a single continuous reciprocating stroke between the corrected first reversing point P1 and the second reversing point P2 during each layer of winding and take-up. The total length of the single continuous reciprocating stroke, |P2-P1|, increases from L as the number of take-up layers increases. cyl Gradually expand to L cyl +L cone After each layer of wiring is completed, the PLC controller re-triggers the winding diameter calculation module, the tapered wiring displacement deviation calculation module, and the wiring parameter correction module to perform a new round of calculations, forming a closed-loop control.

9. The enameled wire take-up control system for the inclined plane composite take-up reel according to claim 8, characterized in that, The PLC controller is equipped with a regional differentiation control module, which includes: The region identification unit is used to determine whether the cable tray is in the conical region or the cylindrical region based on its current position. The PID parameter switching unit is used to switch the PID control parameter group of the cable controller to the pre-stored parameter group corresponding to the current region when a region switch is detected. The step size switching unit is used to switch the ribbon cable step size to the step size value corresponding to the current area when a region switch is detected.

10. The enameled wire take-up control system for the inclined plane composite take-up reel according to claim 8, characterized in that, It also includes an automatic calibration module, which is configured within the PLC controller to perform the following automatic calibration steps: recording the cable routing reference position L0 in an empty reel state, and recording the winding diameter D after winding a preset number of layers n. n And the new position L of the reference position of the cable n Calculate the axial offset ΔL = L n - L0, and according to K = ΔL / (D n - D0) Automatically calculates and updates the taper ratio coefficient K.

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