Alloy steel wire drawing die wear prediction and compensation method

Abstract

The present application relates to the technical field of metal wire drawing process monitoring and control, and particularly relates to a kind of alloy steel wire drawing die wear prediction and compensation method.The method obtains accumulated over wire quantity, drawing force, die temperature, steel wire outlet diameter and process control parameters, forms die wear state, wear prediction result and steel wire quality deviation state;Accordingly determine compensation requirement, and according to target drawing pass and associated pass process control parameters and allowable control range determine remaining control margin and compensation feasible state;In compensable state, allocate compensation requirement, form compensation control configuration and adjust process control parameters;Compare drawing force, die temperature and steel wire outlet diameter before and after adjustment, form compensation review result, and update wear control state and compensation qualification.The present application makes wear prediction, compensation capability determination, multi-pass compensation control and compensation review form continuous control relationship, and generates die change state when compensation is not possible or compensation fails.

Description

Technical Field

[0001] This invention relates to the field of monitoring and control technology for metal wire drawing processes, and in particular to a method for predicting and compensating for wear of alloy steel wire drawing dies. Background Technology

[0002] In the field of metal wire drawing process monitoring and control technology, alloy steel wires typically undergo multiple drawing passes with continuous diameter reduction. Each drawing pass is equipped with corresponding drawing dies, drums, and control mechanisms. Existing solutions usually collect data on drawing force, die temperature, drawing speed, wire exit diameter, or cumulative wire feed to monitor and predict the wear degree, aperture change, or remaining service status of the drawing dies. On the other hand, the drawing production line can also adjust the drum speed and corresponding process control parameters based on changes in tension, speed, or drawing resistance. Such solutions can separately complete die condition monitoring and drawing process adjustment. However, when the drawing dies experience progressive wear and the quality of the steel wire begins to change, insufficient coordination can easily occur between the die wear status and the production process control.

[0003] Existing die wear monitoring schemes mostly determine whether a die needs to be replaced based on the amount of wear, remaining life, or preset scrap conditions. Drawing process control, on the other hand, often relies on adjustments to parameters triggered by deviations in current tension, speed, or drawing resistance. When the target drawing die has not yet reached the replacement condition, but its wear has already caused a shift in the wire exit diameter, simply relying on the degree of wear is insufficient to reflect whether the current drawing pass still has suitable process space for further adjustment. Furthermore, in multi-pass continuous drawing, there is a speed matching and tension transmission relationship between adjacent drawing passes. Adjusting the process control parameters of the target drawing pass individually can easily cause new deviations in the operating state between the target drawing pass and related passes.

[0004] Furthermore, existing solutions, after adjusting process parameters, typically focus on whether the wire size, tension, or drawing resistance returns to the set range. They fail to adequately consider the continuous relationship between the adjusted wire exit diameter, drawing force, and die temperature and the original die wear state. When the wire exit diameter temporarily recovers, but the drawing force or die temperature continues to change, relying solely on a single quality result makes it difficult to determine whether the current process adjustment is still suitable for continuation, and also makes it difficult to determine the timing for subsequent control or die replacement. Therefore, it is necessary to address the connection between the die wear state, wire quality state, and process control state during multi-pass continuous drawing of alloy steel wire, and to solve the problem of the difficulty in continuously coordinating production compensation and subsequent wear state determination under progressive die wear conditions. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides a method for predicting and compensating wear on alloy steel wire drawing dies, comprising: S100: Obtain the cumulative wire feed, drawing force, die temperature, wire exit diameter, process control parameters, allowable control range, and process constraints for each drawing pass; determine the die wear state and wear prediction results of the target drawing die based on the changes in drawing force and die temperature with the cumulative wire feed; and generate the wire quality deviation state based on the wire exit diameter. S200. Based on the wear state of the mold, the wear prediction result, and the quality deviation state of the steel wire, determine the compensation requirement; determine the remaining control margin according to the process control parameters and allowable control range of the target drawing pass and related passes corresponding to the target drawing mold; compare the compensation requirement with the remaining control margin to generate a compensation feasibility state. S300: When the compensation feasible state is a compensable state, the compensation requirement is allocated according to the process constraints and remaining control margin, the compensation control configuration of the target drawing pass and associated pass is generated, and the process control parameters are adjusted according to the compensation control configuration. S400: Obtain the adjusted drawing force, die temperature, and wire exit diameter, compare them with the data before adjustment, and generate a compensation verification result; update the wear control status and compensation eligibility based on the compensation verification result; when the compensation feasible status is an uncompensable status or the compensation verification result is a compensation failure, generate a die change status.

[0006] Furthermore, the cumulative wire feed, drawing force, die temperature, wire exit diameter, and process control parameters are established in a corresponding relationship according to the number of drawing passes and control cycle; the process control parameters include drum speed and tension-related parameters.

[0007] Furthermore, the drawing force and die temperature of multiple control cycles are arranged according to the cumulative wire feed amount; the die wear state is determined based on the continuous state changes of the drawing force and die temperature, and a wear prediction result is generated based on the state changes of the die wear state with the cumulative wire feed amount.

[0008] Furthermore, the wire outlet diameter is compared with the allowable mass range to generate a wire mass deviation state; based on the wire mass deviation state, the mold wear state, and the wear prediction results, the adjustment amount of the process control parameters is determined, and the adjustment amount is determined as the compensation requirement.

[0009] Furthermore, the current process control parameters of the target drawing pass and related passes are compared with the upper or lower limit of the corresponding allowable control range, and the difference between the current process control parameters and the corresponding upper or lower limit is determined as the remaining control margin.

[0010] Furthermore, the compensation requirement is compared with the remaining control margin of the target drawing pass and related passes; if the compensation requirement is within the remaining control margin and the compensated process control parameters are within the allowable control range, the compensation feasible state is determined to be a compensable state; otherwise, it is determined to be an uncompensable state.

[0011] Furthermore, when the compensation feasibility state is a compensateable state, the compensation demand is first allocated to the target pull-out track; when the remaining control margin of the target pull-out track is less than the compensation demand, the unallocated compensation demand is allocated to the associated track according to the remaining control margin of the associated track, generating the target pull-out track control quantity and the associated track control quantity.

[0012] Furthermore, after executing the compensation control configuration, the wire outlet diameter, drawing force, and die temperature are obtained; the wire outlet diameter, drawing force, and die temperature before and after executing the compensation control configuration are compared respectively, and a compensation review result is generated based on the comparison result, indicating whether the compensation is effective, partially effective, or ineffective.

[0013] Furthermore, when the wire exit diameter is within the allowable quality range and the drawing force and die temperature do not change continuously, the compensation generation is effective; when the wire exit diameter is within the allowable quality range and the drawing force or die temperature changes continuously, the compensation generation is partially effective; when the wire exit diameter is not within the allowable quality range, the compensation generation fails.

[0014] Furthermore, if the compensation review result is valid, the compensation qualification is retained; if the compensation review result is partially valid, the mold wear state is updated and the compensation requirement is redefined; if the compensation review result is invalid, the compensation qualification is cancelled and a mold change state is generated. The cumulative wire passage corresponding to the first formation of the wire quality deviation state requiring compensation is determined as the abnormal start position. The wire section to be isolated is determined based on the cumulative wire passage corresponding to the abnormal start position and the current cumulative wire passage when the mold change state is generated.

[0015] The key innovations of this invention include: (1) The wear status of the mold, the wear prediction result and the quality deviation status of the steel wire are converted into compensation requirements. The current process control parameters and allowable control range of the target drawing pass and related passes are converted into the remaining control margin. The compensation feasibility status is formed by comparing the compensation requirements and the remaining control margin, so that the mold wear status and the actual adjustable range of the current production line are directly controlled.

[0016] (2) When the compensation is feasible, the compensation demand is processed together with the process constraints of the target drawing pass, the associated pass and their respective remaining control margins. The target drawing pass first assumes the corresponding control quantity. When its remaining control margin is insufficient, the unallocated compensation demand is further allocated according to the remaining control margin of the associated pass, forming a compensation control configuration consisting of the target drawing pass control quantity and the associated pass control quantity.

[0017] (3) Compare the wire outlet diameter, drawing force and die temperature before and after the compensation control configuration is executed. Based on whether the wire outlet diameter is within the allowable quality range and whether the drawing force and die temperature continue to change continuously, form a compensation review result of compensation effectiveness, compensation partial effectiveness or compensation failure. Update the wear control status and compensation qualification with the compensation review result. When compensation fails, switch to die replacement status.

[0018] The following are its main beneficial effects: (1) By forming compensation demand and remaining control margin separately, and comparing the two before compensation is executed, the steel wire quality deviation caused by progressive die wear is made to correspond with the current actual adjustable space of the drawing pass, thereby reducing the problem of unclear control boundary caused by directly adjusting process control parameters based solely on wear degree, remaining life or single quality deviation.

[0019] (2) By constraining the allocation of compensation demand according to the remaining control margin of the target pulling track and the associated track, the associated track will bear the unallocated part when the target pulling track itself has insufficient adjustment space. This can reduce the deviation of speed matching and tension transmission relationship between the front and rear tracks caused by separately expanding the control amount of the target pulling track, and keep the compensation control within the allowable control range corresponding to each pulling track.

[0020] (3) By using the recovery status of the wire outlet diameter together with the continuous changes in the drawing force and the die temperature for compensation verification, it is possible to distinguish the situation where the wire size has been restored but the drawing die operation status continues to change. Based on this, the wear control status and subsequent compensation eligibility can be updated, reducing the unclear connection between wear status judgment and subsequent die change control caused by continuously implementing compensation based solely on the single wire quality result. Attached Figure Description

[0021] Figure 1 This is a flowchart illustrating a method for predicting and compensating wear of alloy steel wire drawing dies, provided in an embodiment of this application. Detailed Implementation

[0022] Example 1: Refer to Figure 1 This is a flowchart illustrating a method for predicting and compensating wear of alloy steel wire drawing dies according to an embodiment of the present invention. The process may include at least steps S100-S400: S100: Obtain the cumulative wire feed, drawing force, die temperature, wire exit diameter, process control parameters, allowable control range, and process constraints for each drawing pass; determine the die wear state and wear prediction results of the target drawing die based on the changes in drawing force and die temperature with the cumulative wire feed; and generate the wire quality deviation state based on the wire exit diameter. S200. Based on the wear state of the mold, the wear prediction result, and the quality deviation state of the steel wire, determine the compensation requirement; determine the remaining control margin according to the process control parameters and allowable control range of the target drawing pass and related passes corresponding to the target drawing mold; compare the compensation requirement with the remaining control margin to generate a compensation feasibility state. S300: When the compensation feasible state is a compensable state, the compensation requirement is allocated according to the process constraints and remaining control margin, the compensation control configuration of the target drawing pass and associated pass is generated, and the process control parameters are adjusted according to the compensation control configuration. S400: Obtain the adjusted drawing force, die temperature, and wire exit diameter, compare them with the data before adjustment, and generate a compensation verification result; update the wear control status and compensation eligibility based on the compensation verification result; when the compensation feasible status is an uncompensable status or the compensation verification result is a compensation failure, generate a die change status.

[0023] S100: Obtain the cumulative wire feed, drawing force, die temperature, wire exit diameter, process control parameters, allowable control range, and process constraints for each drawing pass; determine the die wear state and wear prediction results of the target drawing die based on the changes in drawing force and die temperature with the cumulative wire feed; generate the wire quality deviation state based on the wire exit diameter. This embodiment is applied to a multi-pass continuous drawing production line for alloy steel wire. Each drawing pass has a drawing die and a drum sequentially arranged along the wire's running direction. The drum is driven by a corresponding speed-regulating motor. The drawing force is obtained by a drawing force detection device located at the corresponding drawing pass. The die temperature is obtained by a temperature sensor located at the drawing die or die mounting base. The wire exit diameter is obtained by a diameter measuring device located downstream of the drawing die. The controller is connected to the drawing force detection device, temperature sensor, diameter measuring device, and drum driver, and reads the current drum speed and tension-related parameters from the drum driver. The cumulative wire throughput is obtained by a meter counter, or by integrating and accumulating the data based on the drawing speed within the control cycle. Both accumulation methods establish a correspondence between the drawing pass and the control cycle, and do not combine the operating amounts of different drawing dies into the cumulative wire throughput of the same die.

[0024] The controller reads the cumulative wire feed, drawing force, die temperature, wire exit diameter, and process control parameters for each drawing pass according to a preset control cycle. The data for each control cycle is correlated with the corresponding drawing pass. After a drawing die is replaced, the starting position for the cumulative wire feed corresponding to that die is re-established, while the consecutive numbers of the drawing passes are retained. Therefore, the die states before and after replacement for the same drawing pass do not form a continuous wear sequence. In one embodiment, each drawing die is equipped with a die identifier. The controller correlates the die identifier with the drawing pass, the starting point of the cumulative wire feed, and the replacement time. When a die is replaced in the same pass, a new wear state sequence is established using the new die identifier. If the complete drawing force, die temperature, or wire exit diameter is not obtained within a control cycle, the data for that control cycle does not participate in the die wear state upgrade. The controller retains the wear state from the previous valid control cycle and re-collects the missing data in the next control cycle.

[0025] For drawing force and die temperature, the die wear state is not determined directly based on a single sampled value. The controller arranges the drawing force and die temperature for multiple control cycles according to the cumulative wire passage and compares their direction of change in continuous control cycles. Specifically, after the drawing die is put into stable drawing, multiple control cycles in which the wire exit diameter is within the allowable quality range and the process control parameters remain stable are selected to form the drawing force reference state and die temperature reference state for the corresponding drawing pass; subsequent control cycles calculate the offset of the drawing force relative to the drawing force reference state and the offset of the die temperature relative to the die temperature reference state, respectively. When the drawing speed or tension-related parameters are actively adjusted, the jump in drawing force or temperature generated in the first control cycle after the adjustment is not directly included in the wear state change. Instead, the corresponding state data is arranged again after the process control parameters reach a new stable state, avoiding mixing the transient changes caused by the control action with the gradual wear of the drawing die.

[0026] Within the same drawing pass, if the drawing force and die temperature remain near the corresponding reference state as the cumulative wire feed increases, the current die wear state of the drawing die is maintained. If the drawing force or die temperature continuously shifts in the same direction relative to the reference state over multiple consecutive control cycles, a corresponding state change is formed. The controller further checks the changes in another physical quantity and the wire exit diameter: when both the drawing force and die temperature show continuous state changes, or when one of them shows a continuous state change and the wire exit diameter continuously shifts relative to the normal processing stage, the drawing die corresponding to that drawing pass is taken as the target drawing die, and its die wear state is updated. If the drawing force suddenly increases but the die temperature and wire exit diameter do not change accordingly, the die wear state is not increased based on this single change, and the controller continues to collect data for subsequent control cycles. This process is used to distinguish between local fluctuations in wire material, instantaneous changes in lubrication state, and state changes caused by continuous wear of the drawing die.

[0027] After the die wear state forms a sequential sequence with the cumulative wire feed, the controller determines the wear prediction result based on the wear state changes between multiple adjacent effective control cycles. In one embodiment, the cumulative wire feed corresponding to the wear state changes is arranged, and the current wear change trend is obtained based on the degree of change in die wear state within a unit cumulative wire feed. Then, combined with the current cumulative wire feed and the preset wear control boundary, the direction of wear state change of the target drawing die within the subsequent cumulative wire feed range and the predicted cumulative wire feed corresponding to reaching the wear control boundary are obtained. The wear prediction result is not used as a direct basis for die replacement, but enters S200 together with the current die wear state; when the current wear state has not yet reached the wear control boundary, but the wear prediction result indicates that it is developing towards the wear control boundary, the subsequent compensation requirement calculation is still based on the current wire quality deviation and the existing process control capability.

[0028] The wire quality deviation status is formed based on the wire exit diameter corresponding to the target drawing die. The diameter measuring device continuously acquires the wire exit diameter after drawing, and the controller compares the wire exit diameter with the allowable quality range corresponding to the current specification. When the wire exit diameter is within the allowable quality range, the wire quality deviation status indicates that the current size is within the allowable quality range. When the wire exit diameter is higher than the upper limit of the allowable quality range or lower than the lower limit of the allowable quality range, the wire quality deviation status retains both the offset direction and the offset amount. For production lines where the diameter measuring device is located downstream of the target drawing die rather than immediately adjacent to the die exit, the controller corrects the wire running path between the target drawing die and the diameter measuring position and the control cycle corresponding to the current drawing speed correction data to make the measured wire exit diameter correspond to the cumulative wire passage amount when the wire passes through the target drawing die. Subsequently, S200 reads the die wear status, wear prediction results, and wire quality deviation status according to this correspondence.

[0029] S200. Based on the die wear state, wear prediction results, and wire quality deviation state, determine the compensation requirement; determine the remaining control margin according to the process control parameters and allowable control range of the target drawing die and related drawing passes; compare the compensation requirement with the remaining control margin to generate a compensation feasibility state: S200 is initiated by the controller after the target drawing die is determined in S100. It reads the die wear status, wear prediction results, and wire quality deviation status of the target drawing die, and simultaneously reads the current process control parameters of the target drawing pass and related passes. The related passes are drawing passes that have a continuous feeding, speed matching, or tension transmission relationship with the target drawing pass. In a multi-pass continuous drawing production line, the drawing pass preceding and following the target drawing pass can be determined as related passes based on the actual tension transmission relationship. If one of the drawing passes is not currently participating in continuous drawing, it will not be included in the compensation allocation for this control cycle.

[0030] The compensation requirement represents the adjustment amount of the process control parameters corresponding to both the current wire quality deviation and the wear state of the target drawing die. In one embodiment, the production line establishes a response relationship between the change in wire exit diameter and the adjustment amount of the drum speed when the drawing die is in normal processing. This response relationship is stored separately according to wire specifications and drawing passes. After entering S200, the controller first determines the adjustment direction of the process control parameters based on the offset direction of the wire exit diameter relative to the allowable quality range, and then reads the initial adjustment amount corresponding to the response relationship based on the exit diameter offset. Subsequently, the initial adjustment amount is corrected by combining the die wear state and wear prediction results. When the wear prediction result indicates that the wear state of the target drawing die remains stable within the subsequent cumulative wire passing amount, the current control cycle adopts the adjustment amount corresponding to the quality deviation; when the wear prediction result indicates that the die wear state continues to develop towards the wear control boundary, the adjustment amount exceeding the current allowable control range is not expanded, but the prediction result is used as a constraint condition for whether to continue allocating compensation requirements in this control cycle.

[0031] In another implementation, instead of using a pre-formed discrete correspondence table, the change in wire exit diameter before and after changes in process control parameters is recorded during normal processing, forming a response relationship between process control parameters and wire exit diameter. S200 divides the current wire quality deviation by the unit change in the corresponding response relationship to obtain the process control parameter adjustment amount for the current control cycle. For production lines where both drum speed and tension-related parameters are adjusted simultaneously, the compensation requirement includes both drum speed adjustment and tension-related parameter adjustment. Each adjustment amount maintains its own physical quantity and adjustment direction, and control parameters with different dimensions are not directly added together. If the current wire exit diameter is still within the allowable quality range, but the die wear condition has changed continuously, no new compensation requirement is generated; the current process control parameters remain unchanged, and no additional compensation is implemented prematurely. When the subsequent wire exit diameter deviates, the process control parameter adjustment amount is then formed based on the deviation.

[0032] The remaining control margin is calculated based on the position of the current process control parameter relative to the allowable control range for the target drawing pass and associated passes. For process control parameters requiring upward adjustment, the controller calculates the difference between the upper limit of the allowable control range and the current process control parameter; for process control parameters requiring downward adjustment, it calculates the difference between the current process control parameter and the lower limit of the allowable control range, and the resulting difference is used as the remaining control margin in the corresponding adjustment direction. In one embodiment, allowable control ranges are set for drum speed and tension-related parameters, and allowable adjustment amounts are set for a single control cycle. When the remaining control margin obtained from the allowable control range is greater than the allowable adjustment amount for a single control cycle, the allowable adjustment amount for the single control cycle is used as the remaining control margin that can be allocated in this control cycle. The portion not executed in this cycle is left to be recalculated in subsequent control cycles, rather than being directly used across cycles.

[0033] Process constraints are involved in the calculation of the effective range of the remaining control margin. Changes in the drum speed of the target drawing pass alter the speed relationship of the wire before and after that pass, and also change the tension state between the target drawing pass and related passes. Therefore, the entire adjustable range cannot be determined solely based on the allowable speed range of a single drum. The controller first checks the adjusted speed matching relationship according to the current changes in wire cross-section and continuous feeding relationship for each drawing pass, and then checks whether the tension-related parameters of the target drawing pass and related passes are still within the corresponding allowable control range. If an adjustment direction, although not exceeding the upper or lower speed limit of a single drum, causes the tension-related parameters of related passes to exceed the allowable control range, this adjustment amount is deducted from the remaining control margin.

[0034] The feasibility of compensation is determined by comparing the compensation requirement with the remaining control margin. For implementations that adjust only one process control parameter, if the adjustment direction corresponding to the compensation requirement is consistent with the direction of the remaining control margin, and the compensation requirement is not greater than the remaining control margin that can be allocated to the target drawing pass and the associated pass under process constraints, then the feasibility of compensation is a compensable state; if the compensation requirement exceeds the remaining control margin, or the compensated process control parameter will exceed the allowable control range, then the feasibility of compensation is an uncompensable state. For cases where multiple process control parameters participate in compensation, the compensation requirement and corresponding remaining control margin of each process control parameter are checked separately. If any necessary control parameter cannot meet the current compensation requirement and the unallocated portion cannot be borne by the associated pass, the current control cycle will not enter the compensation execution branch of S300, but will generate a mold change state in the mold change branch corresponding to S400.

[0035] When there is a conflict between the drawing force, die temperature, and wire exit diameter of the target drawing die, S200 does not directly increase the compensation requirement based on a single anomaly. For example, if the wire exit diameter deviates from the allowable mass range, but the drawing force and die temperature do not show continuous changes corresponding to the wear state in S100, the controller retains the current die wear state and re-acquires the state in the next control cycle; if the same dimensional deviation still occurs in consecutive control cycles, the compensation requirement is recalculated. The compensation requirement confirmed by S200, the remaining control margin of the target drawing pass and related passes, and the compensation feasibility status are sent to S300. S300 does not re-estimate the degree of die wear, but allocates the compensation requirement within the aforementioned control boundaries.

[0036] S300: When the compensation feasibility state is a compensateable state, allocate the compensation demand according to the process constraints and remaining control margin, generate the compensation control configuration for the target drawing pass and associated passes, and adjust the process control parameters according to the compensation control configuration: S300 enters the control execution branch only after S200 outputs a compensable state. The controller first reads the adjustment direction and amount of the compensation requirement, and then reads the remaining control margin of the target drawing pass and associated passes. The allocation sequence starts with the target drawing pass, first checking the control amount that the target drawing pass can handle under the current process constraints. If the remaining control margin of the target drawing pass is greater than or equal to the compensation requirement, the compensation requirement is allocated to the target drawing pass. The associated passes maintain their current process control parameters, unless adjusting the target drawing pass alone would cause the speed or tension relationship between it and the associated passes to exceed the process constraints. In this case, the associated passes are adjusted synchronously according to the matching control amount required to maintain the process constraints.

[0037] When the remaining control margin of the target drawing pass is less than the compensation requirement, the controller first limits the control amount that the target drawing pass can handle to within its remaining control margin. The difference between the compensation requirement and this control amount forms the unallocated compensation requirement. Subsequently, the remaining control margin of the associated passes in the same adjustment direction or in the matching adjustment direction is read. Based on the speed matching relationship and tension transmission relationship between the associated passes and the target drawing pass, the unallocated compensation requirement is converted into the process control parameter adjustment amount corresponding to the associated pass. In an implementation with multiple associated passes, the associated passes that are directly adjacent to the target drawing pass and have a tension transmission relationship are allocated first. If the remaining control margin of one associated pass is insufficient, the unallocated portion is then sent to another associated pass that meets the process constraints, until the compensation requirement is allocated or the existing remaining control margin can no longer handle the unallocated portion.

[0038] When compensation requirements are allocated across different drawing passes, identical values ​​are not directly copied. For drum speed control, the controller converts the unallocated speed adjustment requirements of the target drawing pass into the corresponding speed adjustment amount for the associated passes based on the current wire cross-sectional changes and speed relationship between the target drawing pass and the associated passes. For tension-related parameter control, the matching direction is determined based on the current tension state at the inlet and outlet sides of the target drawing pass. The converted control amount for the associated pass is then compared with the remaining control margin of that associated pass. If the conversion result exceeds the remaining control margin, the control amount for the associated pass is limited to the remaining control margin, and the aforementioned allocation process continues for the remaining unallocated portion. If, during the allocation process, all associated passes reach the remaining control margin but the compensation requirement is still not fully allocated, the parameter adjustment for this control cycle is terminated, the compensation feasible state is changed to an uncompensable state, and the die-changing branch is entered, without exceeding the allowable control range by expanding the control amount of a single pass.

[0039] After the compensation demand allocation is completed, the controller forms a compensation control configuration. This compensation control configuration corresponds to the current control cycle and includes the target drawing pass control quantity, associated pass control quantities, and the process control parameters corresponding to each control quantity. The control quantities for multiple drawing passes use the same control cycle reference, ensuring that each speed-regulating motor completes parameter changes within a predetermined control time. For control configurations where the change magnitude is close to the allowable adjustment amount for a single control cycle, in one implementation, the drum speed or tension-related parameters are changed segment by segment according to multiple consecutive control sub-cycles. After each control sub-cycle is completed, the current value of the driver is read; the next control sub-cycle begins only after the actual value reaches the control quantity of the current sub-cycle. If the actual value of the driver does not reach the corresponding control quantity, subsequent adjustments are not increased; instead, the current stable process control parameters are retained, and the execution status is rechecked.

[0040] The execution sequence of the compensation control configuration is arranged according to the wire running relationship between the target drawing pass and related passes. If an increase in the target drawing pass speed will first change the exit-side tension, the related exit-side passes will first enter the corresponding coordination state before adjusting the target drawing pass. If a decrease in the target drawing pass speed will first change the inlet-side tension, the coordination control quantity is arranged according to the current tension state of the related inlet-side passes. This execution sequence is determined based on the existing speed and tension relationship of the production line and is not a fixed requirement for all related passes to start simultaneously. After all control quantities are executed, the controller records the cumulative wire passage at the time of completion. This cumulative wire passage serves as the starting point for S400 to determine when the compensated wire reaches the diameter measurement position.

[0041] If a reel driver is in a fault, speed-limited, or unresponsive state during execution, the corresponding process control parameters are not considered as completed compensation. The controller stops allocating remaining compensation requirements and maintains the process control parameters of the non-faulty pull-out passes within the most recent allowable control range. For short-term communication interruptions, the controller waits for the next control cycle to reread the actual values ​​of the driver. If the driver status still does not correspond to the compensation control configuration, this action is not considered valid compensation for normal verification in S400; instead, the compensation feasibility check is re-executed as if compensation is incomplete. Only after the target pull-out pass control quantity and the associated pass control quantity to be executed in the compensation control configuration both reach the corresponding process control parameters will the compensation response acquisition in S400 be initiated.

[0042] S400: Obtain the adjusted drawing force, die temperature, and wire exit diameter, compare them with the data before adjustment, and generate a compensation verification result; update the wear control status and compensation eligibility based on the compensation verification result; when the compensation feasibility status is an uncompensable status or the compensation verification result is a compensation failure, generate a die change status: After S300 completes the compensation control configuration, S400 does not directly use the wire exit diameter obtained at the moment the control command is issued as the compensation result. There is a wire travel distance between the target drawing die and the diameter measuring device. Wires that have left the target drawing die but have not yet reached the diameter measuring device when the control action occurs still correspond to the pre-adjustment working condition. The controller determines the starting position of the wire entering the diameter measuring position after compensation based on the cumulative wire passage at the time of completion of the compensation control configuration and the wire travel path between the target drawing die and the diameter measuring position. In one embodiment, the state transfer time is calculated based on the wire travel path and the current drawing speed. After the state transfer time has elapsed, the wire exit diameter is read. Simultaneously, the drawing force and die temperature corresponding to this stage are read to form the adjusted drawing operation state and wire quality state.

[0043] The compensation verification involves comparing similar physical states before and after the compensation control configuration. The controller reads the wire exit diameter, drawing force, and die temperature, which were already associated with the target drawing die before adjustment, and then reads the corresponding data for multiple consecutive control cycles after compensation. The wire exit diameter is first compared with the allowable mass range, while the drawing force and die temperature are compared with the direction of continuous state change before adjustment. Here, "no continuous state change" means that within multiple effective control cycles after compensation, the drawing force and die temperature no longer continue to change along the continuous offset direction when S100 forms the die wear state; local fluctuations in a single control cycle but subsequent control cycles returning to the stable range after compensation are not considered continuous state changes.

[0044] When the wire exit diameter enters the allowable quality range, and the compensated drawing force and die temperature do not continue to show continuous changes consistent with the wear development direction, the compensation verification result is considered valid. The controller retains the compensation eligibility of the current target drawing die and uses the compensated process control parameters as the current process control parameters for the next control cycle; the next control cycle re-executes the state arrangement of S100, without directly using the compensation requirements of the previous cycle. Thus, if the die wear state changes again after the subsequent cumulative wire feed increases, S200 recalculates the control boundary based on the new quality deviation state and the new remaining control margin, instead of repeatedly executing the previous compensation control configuration.

[0045] When the wire exit diameter has entered the allowable quality range, but the drawing force or die temperature continues to change continuously along the original wear direction within multiple effective control cycles, the compensation verification result is that the compensation is partially effective. This state indicates that the current process parameter adjustment has restored the exit diameter to the allowable quality range, but the operating state corresponding to the drawing die has not stopped changing. The controller updates the die wear state accordingly and adds the compensated drawing force and die temperature to the state sequence of the target drawing die arranged according to the cumulative wire passage. Then, it re-enters S200 according to the updated die wear state and wear prediction results. At this time, instead of directly increasing the control quantity based on the original compensation control quantity, the wire quality deviation state, compensation requirement, and remaining control margin are recalculated. If the new compensation requirement exceeds the existing remaining control margin, it is converted to an uncompensable state.

[0046] If, after executing the compensation control configuration, the wire exit diameter still fails to enter the allowable quality range after the corresponding state transition time, the compensation verification result is compensation failure. If the wire exit diameter continues to deviate from the allowable quality range in multiple consecutive control cycles, the compensation failure state is also maintained, and the compensation process is not prolonged by repeatedly increasing the target drawing pass control quantity. After compensation failure, the compensation qualification of the target drawing die is cancelled, and the controller generates a die-changing state. If S200 has already obtained an uncompensable state, the process control parameter adjustment in S300 is not executed, and a die-changing state is also generated in S400, so that the two abnormal paths of "insufficient control capability" and "actual compensation invalid" merge into the same die-changing process.

[0047] After generating the die-changing state, the controller stops calculating new compensation requirements for the target drawing die and records the cumulative wire passage amount corresponding to the abnormal starting position. The abnormal starting position is taken as the cumulative wire passage amount corresponding to the first occurrence of the wire quality deviation state requiring compensation. If there is a wire running path between the diameter measuring device and the target drawing die, the cumulative wire passage amount of the detected dimensional abnormality is converted to the position when the wire passes through the target drawing die according to the data correspondence established in S100. When generating the die-changing state, the current cumulative wire passage amount is read again, with the cumulative wire passage amount corresponding to the abnormal starting position as the starting boundary of the wire section to be isolated, and the current cumulative wire passage amount when generating the die-changing state as the ending boundary. After the production line completes the shutdown, the corresponding continuous wire section is marked according to the cumulative wire passage amount. After subsequent die-changing is completed, the cumulative wire passage starting point and die wear state sequence are re-established for the new drawing die.

[0048] For wire sections that have been compensated before the die change state is generated and whose verification results show that the compensation is effective, the controller retains the cumulative wire passage range corresponding to the section and determines whether to include it in the wire section to be isolated based on whether the actual wire exit diameter within this range is within the allowable quality range. Continuous sections within the allowable quality range will not automatically expand the isolation boundary due to subsequent die change states, while continuous sections outside the allowable quality range will be included in the wire section to be isolated from the corresponding abnormal starting position. After the drawing die is replaced and production restarts, the wear control state and compensation qualification corresponding to the old die will stop participating in the new control cycle, and the new die will re-establish the state sequence between drawing force, die temperature, wire exit diameter and cumulative wire passage according to S100.

Claims

1. A method for predicting and compensating wear of alloy steel wire drawing dies, characterized in that, include: S100: Obtain the cumulative wire feed, drawing force, die temperature, wire exit diameter, process control parameters, allowable control range, and process constraints for each drawing pass; determine the die wear state and wear prediction results of the target drawing die based on the changes in drawing force and die temperature with the cumulative wire feed; and generate the wire quality deviation state based on the wire exit diameter. S200. Based on the wear state of the mold, the wear prediction result, and the quality deviation state of the steel wire, determine the compensation requirement; determine the remaining control margin according to the process control parameters and allowable control range of the target drawing pass and related passes corresponding to the target drawing mold; compare the compensation requirement with the remaining control margin to generate a compensation feasibility state. S300: When the compensation feasible state is a compensable state, the compensation requirement is allocated according to the process constraints and remaining control margin, the compensation control configuration of the target drawing pass and associated pass is generated, and the process control parameters are adjusted according to the compensation control configuration. S400: Obtain the adjusted drawing force, die temperature and wire exit diameter, compare them with the data before adjustment, and generate compensation verification results; The wear control status and compensation eligibility are updated based on the compensation review results; when the compensation feasibility status is an uncompensable status or the compensation review results indicate compensation failure, a mold change status is generated.

2. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 1, characterized in that, The cumulative wire feed, drawing force, die temperature, wire exit diameter, and process control parameters are established in a corresponding relationship according to the number of drawing passes and control cycle; the process control parameters include drum speed and tension-related parameters.

3. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 2, characterized in that, The drawing force and die temperature of multiple control cycles are arranged according to the cumulative wire feed amount; the die wear state is determined based on the continuous state changes of the drawing force and die temperature, and a wear prediction result is generated based on the state changes of the die wear state with the cumulative wire feed amount.

4. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 3, characterized in that, The wire outlet diameter is compared with the allowable mass range to generate a wire mass deviation state; the adjustment amount of the process control parameters is determined based on the wire mass deviation state, the mold wear state, and the wear prediction results, and the adjustment amount is determined as the compensation requirement.

5. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 4, characterized in that, The current process control parameters of the target drawing pass and related passes are compared with the upper or lower limit of the corresponding allowable control range, and the difference between the current process control parameters and the corresponding upper or lower limit is determined as the remaining control margin.

6. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 5, characterized in that, The compensation requirement is compared with the remaining control margin of the target drawing pass and related passes; if the compensation requirement is within the remaining control margin and the compensated process control parameters are within the allowable control range, the compensation feasibility state is determined to be a compensable state; otherwise, it is determined to be an uncompensable state.

7. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 6, characterized in that, When the compensation feasibility state is a compensateable state, the compensation demand is first allocated to the target pull-out track; when the remaining control margin of the target pull-out track is less than the compensation demand, the unallocated compensation demand is allocated to the associated track according to the remaining control margin of the associated track, generating the target pull-out track control quantity and the associated track control quantity.

8. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 7, characterized in that, After executing the compensation control configuration, the wire outlet diameter, drawing force, and die temperature are obtained; the wire outlet diameter, drawing force, and die temperature before and after executing the compensation control configuration are compared respectively, and a compensation review result is generated based on the comparison result, indicating whether the compensation is effective, partially effective, or ineffective.

9. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 8, characterized in that, When the wire exit diameter is within the allowable quality range and the drawing force and die temperature do not change continuously, the compensation generation is effective; when the wire exit diameter is within the allowable quality range and the drawing force or die temperature changes continuously, the compensation generation is partially effective; when the wire exit diameter is outside the allowable quality range, the compensation generation fails.

10. The method for predicting and compensating wear of alloy steel wire drawing dies according to claim 9, characterized in that, The compensation review result is that if the compensation is valid, the compensation qualification is retained; if the compensation review result is that the compensation is partially valid, the mold wear status is updated and the compensation requirement is redefined; if the compensation review result is that the compensation is invalid, the compensation qualification is cancelled and a mold change status is generated. The cumulative wire passage corresponding to the first formation of the wire quality deviation status that needs compensation is determined as the abnormal start position. The wire section to be isolated is determined based on the cumulative wire passage corresponding to the abnormal start position and the current cumulative wire passage when the mold change status is generated.

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