An annealing tension cooperative control method and system for enameled wire production

Abstract

This invention proposes a method and system for coordinated control of annealing tension in enameled wire production, belonging to the field of coordinated control technology. It pre-sets and dynamically compensates the tension of the bare copper wire entering the annealing furnace, adjusts the wire-moving speed within the furnace in real time, and uses the outgoing wire elongation status information and current production speed signal to coordinately regulate the deionized water level, water quality, and heating temperature in the water seal tank. It also synchronously controls the operation of the drying device downstream of the water outlet. Based on the qualified annealed wire output quality and the wire breakage detection signal at the take-up device, it provides emergency zero-tension protection for the entire wire in case of breakage, while maintaining the steam protection state of the annealing furnace and obtaining the wire breakage protection judgment result. This invention achieves a coordinated and safe control effect, maintaining the stable geometric dimensions and mechanical properties of the copper wire during annealing, ensuring the continuous effectiveness of the water seal steam protection, and enabling rapid resumption of production without readjustment of parameters after a wire breakage.

Description

Technical Field

[0001] This invention proposes a method and system for coordinated control of annealing tension in enameled wire production, which relates to the field of coordinated control technology, specifically to the field of coordinated control of annealing tension in enameled wire production. Background Technology

[0002] In the continuous production of enameled wire, the annealing process is the core step that determines the final mechanical properties and surface quality of the copper wire. After drawing, the bare copper wire undergoes lattice distortion and increased hardness, requiring annealing to recrystallize and soften it, and to remove residual lubricant and oil from the surface, in order to obtain good softness, elongation, and paint adhesion. Existing annealing control methods suffer from two aspects of synergistic uncontrollability. The copper wire is exposed to a high temperature of 300℃~600℃ in the annealing furnace, significantly reducing its tensile strength. If there is a lack of coordination between the wire tension, assisted traction, and constant-speed traction at this temperature, the copper wire is easily stretched unintended or fails to meet elongation standards. Furthermore, due to the lack of dynamic adjustment methods for DV values, the matching of temperature and speed relies on manual experience, resulting in large fluctuations in product quality. There is a lack of linkage between the water seal protection at the annealing furnace outlet and the winding operation status. When the water level, water quality, and water temperature are not adequately controlled, the copper wire surface is prone to oxidation, affecting the adhesion of the varnish film. After the wire breaks, the winding stop and annealing protection respond independently without coordination, causing the high-temperature copper wire at the break point to remain in the furnace tube for a long time and oxidize. Moreover, when resuming production, the process parameters need to be readjusted, resulting in material waste and low efficiency. Summary of the Invention

[0003] This invention provides a method and system for coordinated control of annealing tension in enameled wire production, to solve the above-mentioned problems: This invention proposes a method for coordinated control of annealing tension in enameled wire production, the method comprising: S1. By coordinating the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor, the tension of the bare copper wire entering the annealing furnace is preset and dynamically compensated to obtain a safe inlet tension value. S2. By using the safe furnace tension value and the actual temperature feedback of the three temperature control zones of the annealing furnace, the line speed in the annealing furnace is matched and adjusted in real time to obtain the annealing DV value range and the corresponding line elongation status information. S3. Based on the elongation status information of the output line and the current production speed signal, the deionized water level, water quality and heating temperature in the water seal tank are adjusted in a coordinated manner, and the operation status of the drying device behind the water outlet is controlled synchronously to obtain qualified annealing output quality. S4. Based on the qualified annealing output quality and the wire breakage detection signal at the take-up device, the tension of the entire wire is reset to zero in an emergency, while maintaining the steam protection state of the annealing furnace, and the wire breakage protection judgment result is obtained.

[0004] Furthermore, the system includes: The safe entry analysis module is used to pre-set and dynamically compensate the tension of the bare copper wire entering the annealing furnace by coordinating the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor, so as to obtain the safe entry tension value. The matching and adjustment module is used to adjust the line speed in the annealing furnace in real time by using the safe furnace tension value and the measured temperature feedback of the three temperature control zones of the annealing furnace to obtain the annealing DV value range and the corresponding line elongation status information. The synchronous control module is used to adjust the deionized water level, water quality and heating temperature in the water seal tank in conjunction with the elongation status information of the output line and the current production speed signal, and to synchronously control the operation status of the drying device behind the water outlet to obtain qualified annealing output quality. The collaborative control module is used to perform emergency zeroing protection for the tension of the entire line based on the qualified annealing output quality and the breakage detection signal at the take-up device, while maintaining the steam protection state of the annealing furnace and obtaining the breakage protection judgment result.

[0005] The beneficial effects of this invention are as follows: By linking four key aspects—tension presetting, DV value matching, water seal linkage adjustment, and wire breakage emergency protection—into a fully coordinated control chain, the problem of response lag and mismatch caused by independent adjustment of process parameters during annealing is solved, achieving full-line coordination from the initial furnace tension to the final wire take-up quality. A dynamic compensation mechanism addresses the tension drift caused by thermal expansion and speed fluctuations in the annealing furnace, ensuring stable initial furnace tension within permissible limits. Real-time matching of wire travel speed based on measured temperature feedback resolves the issue of DV value deviation from the process window, ensuring precise correspondence between annealing degree and copper wire specifications. Linked adjustment of water level, water quality, and water temperature, along with synchronous control of the drying device, solves the problems of water seal failure and oxidation of the exiting wire, resulting in stable and controllable surface quality. The full-line tension zeroing protection triggered by a wire breakage signal and the maintenance of steam protection status resolve the issues of copper wire scrapping and threading difficulties caused by tension loss and high-temperature oxidation at the moment of breakage, reducing breakage processing time and scrap rate, and improving equipment operational safety. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of a method for coordinated control of annealing tension in enameled wire production. Detailed Implementation

[0007] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0008] Example 1

[0009] One embodiment of the present invention provides a method for coordinated control of annealing tension in enameled wire production, the method comprising: S1. By coordinating the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor, the tension of the bare copper wire entering the annealing furnace is preset and dynamically compensated to obtain a safe furnace entry tension value; wherein, the safe furnace entry tension value is equal to the net tension value after the wire feeding resistance corresponding to the clamping force of the wire feeding damping brush and the traction force of the inlet assist motor are superimposed at the annealing furnace entry, and the allowable range of the net tension value is from the lower limit to the upper limit of the tension range corresponding to the current wire gauge in the process standard; S2. By using the safe furnace tension value and the actual temperature feedback of the three temperature control zones of the annealing furnace, the line speed in the annealing furnace is matched and adjusted in real time to obtain the annealing DV value range and the corresponding line elongation status information; wherein, the annealing DV value range is the lower limit of the DV value to the upper limit of the DV value corresponding to the current line gauge in the process parameter table; S3. Based on the elongation status information and the current production speed signal, the deionized water level, water quality, and heating temperature in the water seal tank are adjusted in a coordinated manner, and the operation status of the drying device behind the water outlet is controlled synchronously to obtain qualified annealed wire quality; wherein, the qualified annealed wire quality is the judgment result that the actual elongation is within the target elongation tolerance zone and the color difference grade of the copper wire surface is not greater than the adjacent color level of the standard color card; S4. Based on the qualified annealing output quality and the wire breakage detection signal at the take-up device, perform emergency zero-tightening protection for the entire wire tension, while maintaining the steam protection state of the annealing furnace, and obtain the wire breakage protection judgment result. The wire breakage protection judgment result is the confirmation that after the wire breakage detection signal is triggered, all drive motors on the entire line are stopped, the output power of the annealing furnace electric heating tube is locked at the measured value before the wire breakage, the set temperature of the water seal heater is locked at the set value before the wire breakage, and the operating frequency of the drying device is locked at the operating value before the wire breakage. Figure 1 As shown.

[0010] The basic wire tension is equal to the output resistance value corresponding to when the damping brush clamping force knob is adjusted to the process calibration scale; the assist traction speed value is equal to the real-time linear speed of the constant speed wheel multiplied by the positive deviation coefficient of the fixed linear speed between the constant speed wheel and the assist motor; the compensation rule is that when the dynamic tension feedback value is greater than the upper limit of the safe furnace entry tension value, the frequency converter frequency is reduced by a fixed step size; when the dynamic tension feedback value is less than the lower limit of the safe furnace entry tension value, the frequency converter frequency is increased by a fixed step size. After each compensation operation, wait for a fixed time before performing the next compensation judgment; the stable pre-furnace entry tension is equal to the arithmetic mean of the dynamic tension feedback value when the dynamic tension feedback value is within the allowable range of the safe furnace entry tension value for multiple consecutive sampling cycles; the safe furnace entry tension value is equal to the current value of the stable pre-furnace entry tension after joint debugging confirmation; among them, the fixed step size, fixed time, and subsequent fixed parameters are all stored in the process parameter table. Different wire gauges and paint types correspond to their own independent set of fixed values. When changing product specifications, the corresponding fixed values ​​are automatically called to participate in the calculation.

[0011] The fixed linear speed positive deviation coefficient is the set value for the speed difference between the constant speed wheel and the assist motor. It means that the linear speed of the assist motor is always higher than the linear speed of the constant speed wheel by a fixed percentage. This percentage is derived from the entry corresponding to the current linear gauge in the process parameter table. The base speed of the assist motor is equal to the product of the inverter's initial output frequency and the assist motor's inherent speed conversion factor. The inherent speed conversion factor is the reciprocal of the number of pole pairs of the motor multiplied by a constant. The real-time speed deviation percentage is equal to the percentage obtained by subtracting the constant speed wheel speed from the assist motor speed and then dividing by the constant speed wheel speed. The preset target deviation is fixed as a constant positive deviation percentage value specified by the process. This value and the fixed linear speed positive deviation coefficient are the same values ​​of the same parameter at different stages. The step-by-step approximation adjustment rule is to increase the inverter frequency by a fixed percentage when the real-time speed deviation percentage is lower than the preset target deviation lower limit. A fixed step size is used. When the real-time speed deviation percentage exceeds the preset target deviation upper limit, the inverter frequency is reduced by a fixed step size. The interval between two adjacent adjustment operations is fixed, and this interval is sufficient to allow the motor speed to stabilize to the steady-state value corresponding to the new frequency. The precise assist traction speed is equal to the linear speed of the assist motor when the real-time speed deviation percentage first enters the preset target deviation bandwidth. The alternative positive deviation value is a fixed percentage lower than the preset target deviation. When the motor current exceeds the upper limit of the light load range, the inverter frequency automatically drops to the speed level corresponding to the alternative value and re-executes the step-by-step approximation adjustment. The verification standard is that the assist motor operating current is within the light load allowable current range of the rated current. After verification, the assist traction speed value is equal to the current precise assist traction speed value corresponding to when the assist motor operating current is within the light load allowable current range.

[0012] The actual DV value equals the product of the current line speed and the effective tube length of the annealing furnace, which is a fixed value specified on the equipment nameplate. The recommended DV value range for the target line gauge is derived from the process parameter table, where the upper and lower limits of the DV values ​​for different line gauges and paint types are pre-stored. If the actual DV value is less than the lower limit of the recommended DV value range, a speed-up operation is performed, with the speed-up step size being a fixed increment of the frequency converter frequency. If the actual DV value is greater than the upper limit of the recommended DV value range, a speed-down operation is performed, with the speed-down step size being a fixed increment of the frequency converter frequency. The length is the frequency of the constant-speed wheel inverter reduced by a fixed increment; after a single speed-up or speed-down operation, wait a fixed time before the next comparison and judgment; the criteria for determining stable operation of the line speed are that the current frequency of the constant-speed wheel inverter remains unchanged for multiple consecutive sampling cycles, and the fluctuations of the measured temperature values ​​in the inlet, middle, and outlet zones of the annealing furnace do not exceed their respective allowable bandwidths; the actual elongation is equal to the arithmetic mean of all test values ​​obtained after a specified number of samples are taken for elongation testing after stability is achieved. Sample length and testing standards shall be performed in accordance with the process standard; the standard requires elongation as the nominal elongation specified in the process standard, and its tolerance zone is also stored under the corresponding line gauge entry in the process parameter table; the deviation analysis method is to calculate the difference between the actual elongation and the standard required elongation; the readjustment rule is as follows: if the difference is positive and exceeds the upper tolerance zone, the temperature setting value of each temperature zone of the annealing furnace is reduced by a fixed level; if the difference is negative and exceeds the lower tolerance zone, the temperature setting value of each temperature zone of the annealing furnace is increased by a fixed level. The temperature adjustment level is the process standard. The parameter table stores the minimum temperature change for each step. If the direction of the difference does not change as expected after a stabilization waiting period following temperature adjustment, the frequency of the constant speed wheel inverter is adjusted in fixed steps. The annealed DV value range is equal to the range of the current actual DV value after all adjustments are completed and stabilized. The outgoing line elongation status information is equal to the actual elongation under the stable state and the determination result of the relationship between the actual elongation and the standard required elongation tolerance zone. The relationship is divided into three states: below the lower limit, within the zone, and above the upper limit.

[0013] The recommended DV value range for the target wire gauge and paint type in the process parameter table is from the lower limit to the upper limit of the fixed DV value. Different combinations of wire gauges and paint types correspond to different upper and lower limits. The direction of DV value deviation is when the actual DV value is greater than the upper limit or less than the lower limit. The magnitude of DV value deviation is equal to the absolute value of the difference between the actual DV value and the nearest limit. The adjustment direction is determined by first determining the speed increase or decrease based on the DV value deviation direction, then reading the temperature deviation direction between the measured temperature value at the annealing furnace outlet and the temperature setpoint. If the temperature deviation direction is the same as the DV value deviation direction, the adjustment step size is determined as a full step size; otherwise, it is determined as a half step size. The specific values ​​of the full step size and half step size are pre-stored in the process parameter table. The current speed setpoints of the circulating fan and the exhaust fan are fixed as the standard operating speed values ​​specified by the process. Different wire gauges correspond to different standard operating speed values. The rotational speed is adjusted by increasing or decreasing the step size of the constant-speed wheel inverter according to the direction command and theoretical adjustment step size. After each operation, the temperature in the outlet area is considered to have stabilized again when the fluctuation does not exceed the allowable bandwidth for several consecutive sampling cycles. The surface gloss of the copper wire at the annealing furnace outlet is measured using a gloss meter. The standard color card is a colorimetric tool specified in the process standard for determining the color of the copper wire surface. The abnormal judgment standard is that the color difference grade of the copper wire surface is greater than the adjacent color level of the standard color card or the surface gloss measurement value of the copper wire surface is less than the minimum allowable gloss value specified in the process. The abnormal handling method is to restore the frequency of the constant-speed wheel inverter to the previous valid value before the current adjustment and use the linear speed corresponding to that frequency as the intermediate linear speed for re-comparison. If it still fails after three cycles, an alarm is triggered and automatic adjustment is stopped, waiting for manual intervention.

[0014] The water seal tank has two pre-stored fixed water level thresholds, a high limit and a low limit, corresponding to the float valve's fully closed and fully open positions, respectively. An abnormal float valve status is determined by failure to close when the water level reaches the high limit or failure to open when it reaches the low limit. The water seal's sealing status is determined when the water level is between the high and low limits and the float valve is functioning normally. Conductivity and chloride ion concentration measurements are continuously output by an online water quality analyzer, and the maximum allowable conductivity and chloride ion concentration values ​​specified by the process are stored in the process parameter table. Deionized water replacement is triggered when any measured value exceeds the corresponding maximum allowable value; otherwise, the current water quality is maintained without water replacement. The commissioning confirmation standard for the circulating filtration system is that the operating status signal is "operating" and the flow meter reading is between the lower limit and the process-required flow rate. The upper limit values ​​are defined as follows: Cleaning and protection water information equals a comprehensive judgment result where conductivity and chloride ion concentration are both within allowable ranges and the circulating filtration system is operating normally; the water seal tank heater start-up temperature threshold equals the process target temperature value minus the lower limit of the allowable fluctuation bandwidth, and the stop temperature threshold equals the process target temperature value plus the upper limit of the allowable fluctuation bandwidth; reasonable water temperature equals a continuously stable state where the measured temperature of the water seal tank is within the target temperature value ± allowable fluctuation bandwidth; steam generation equals a state where saturated steam is continuously generated in the water seal tank at a reasonable water temperature; the drying device linkage start-up rule is to start after a fixed delay after the water temperature reaches the standard and the steam stabilizes, with the delay time stored in the process parameter table; qualified annealing output quality equals a comprehensive judgment result where the actual elongation is within the tolerance zone, the color difference is not greater than adjacent color levels, and the gloss is not less than the minimum allowable value.

[0015] The minimum safe water level threshold of the water seal tank is the minimum allowable water level value corresponding to the current production speed in the process standard. Different production speeds correspond to different minimum safe water level values. The reading cycle of the liquid level sensor is fixed to the standard sampling interval set by the system. The current dynamic change trend of the water level is the time series of the water level value and its monotonic change direction within multiple consecutive sampling cycles. The specified response time of the float valve is stored in the process parameter table. If the open / closed status signal does not switch after exceeding the specified response time, it is determined to be a response delay fault. If the water level has exceeded the set limit but the status signal has not switched, it is determined to be a jamming fault. A fixed safety margin is stored in the process parameter table. When the water level reaches the minimum safe water level threshold plus this safety margin, an early water replenishment command is triggered. The process parameters are as follows: The water supply pump is started or the solenoid valve is opened to a fixed degree, which is stored in the process parameter table. The water level recovery curve is the trajectory of water level change over time during the water supply process. The stable water level after water supply is the arithmetic mean of the fluctuations in the water level at the end of the curve over multiple consecutive sampling periods, provided that the fluctuations do not exceed the allowable bandwidth. The target constant water level is the optimal operating water level specified by the process, and the allowable deviation range is stored in the process parameter table. A seal failure is determined when the bubble sensor reading exceeds the maximum allowable bubble generation specified by the process, and a seal failure is determined when the furnace tube outlet negative pressure sensor reading is lower than the minimum allowable negative pressure value. The flow rate adjustment rule for the water seal circulation pump is to reduce the inverter frequency when the deviation is positive and increase the inverter frequency when the deviation is negative; the adjustment ratio is stored in the process parameter table.

[0016] The wire breakage detection switch is a hardware contact sensor, forming a dual-judgment logic with the tension lever position sensor. The trigger condition for the wire breakage sensing signal is that the wire breakage detection switch is in the closed state and the position sensor angle value exceeds the normal operating angle range. The response delay of the PLC controller's stop command is the maximum allowable response delay time of the system, which is stored in the controller parameters. The deceleration slope of the inlet assist motor is the standard deceleration rate value specified by the process, which means the magnitude of frequency reduction per unit time, and is stored in the process parameter table. The hold command for the annealing furnace electric heating tube to maintain the current output value means that the heating power of each temperature zone is locked at the measured value of the last sampling cycle before the wire breakage trigger, and the allowable fluctuation range is limited to a fixed percentage bandwidth of the locked value. The output power of the water seal heater and the operating frequency of the drying fan are also locked at the measured value of the last sampling cycle before the wire breakage trigger. The reset operation confirmation signal is generated after the reset button on the operation panel is continuously pressed for a specified pressing time, and the pressing time is stored in the system parameters. The acceleration curve for resynchronization is a linear rise to a fixed rise time of their respective set frequencies, and the rise time is stored in the process parameter table.

[0017] The measured temperature values ​​of the annealing furnace inlet, middle, and outlet zones are latched at the moment of disconnection triggering, and the latched temperature values ​​serve as the target to be maintained during the disconnection period. The forced instruction locks the output percentage of each temperature zone to the measured percentage value of the last sampling period before the disconnection triggering, with the allowable fluctuation range limited to a fixed percentage bandwidth. The integral and derivative terms of the PID controller are both set to zero, retaining only the current value of the proportional term, thereby blocking the automatic adjustment output of the temperature control module. Steam protection is deemed effective when the steam flow meter reading is consistently not lower than the flow rate corresponding to the minimum steam generation specified by the process. The operating frequency of the vortex pump is locked to the measured value of the last sampling period before the disconnection triggering, with the allowable deviation range limited to a fixed percentage. Percentage bandwidth; the air seal barrier is considered intact when the temperature sensor reading at the hot air curtain outlet is not lower than the minimum allowable temperature value and the wind speed sensor reading is not lower than the minimum allowable wind speed value; fixed detection cycle and fixed observation cycle are stored in the process parameter table. The two cycles can be the same or different, but they are all pre-stored fixed values; all fixed parameters such as fixed step size, fixed duration, fixed increment, fixed gear, fixed percentage bandwidth, fixed proportional coefficient, fixed detection cycle, fixed observation cycle, fixed safety margin, fixed opening degree, fixed rise time, and fixed press time are all pre-stored fixed values ​​in the process parameter table. Different product specifications correspond to their own independent set of parameter values, which are automatically switched when changing product specifications.

[0018] The working principle and technical effects of the above technical solution are as follows: This invention uses the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor to pre-set and dynamically compensate the tension of the bare copper wire at the inlet of the annealing furnace, thereby obtaining a safe inlet tension value; through the feedback of the safe inlet tension value and the measured temperature of the three temperature control zones, the wire speed in the annealing furnace is matched and adjusted in real time to obtain the optimal annealing DV value range and the corresponding wire elongation status information; through the wire elongation status information and the current production speed signal, the deionized water level, water quality and heating temperature in the water seal tank are adjusted in linkage, and the operating status of the drying device after the water outlet is synchronously controlled to obtain qualified annealed wire output quality; through the qualified annealed wire output quality and the wire breakage detection signal at the take-up device, the tension of the entire line is reset to zero in an emergency, while maintaining the steam protection state of the annealing furnace, and obtaining the wire breakage protection judgment result.

[0019] By linking tension presetting, DV value matching, water seal linkage adjustment, and wire breakage emergency protection into a complete process coordinated control chain, the problem of response lag and matching mismatch caused by independent adjustment of process parameters during annealing is solved, achieving full-line coordination from the front-end furnace inlet tension to the back-end wire take-up quality. A dynamic compensation mechanism solves the tension drift problem caused by thermal expansion and speed fluctuations in the annealing furnace, keeping the furnace inlet tension stable within the allowable range. Real-time matching of wire walking speed based on measured temperature feedback solves the problem of DV value deviation from the process window, ensuring precise correspondence between the annealing degree and the copper wire specifications. Linked adjustment of water level, water quality, and water temperature, along with synchronous control of the drying device, solves the problems of water seal failure and water oxidation on the exit wire, ensuring stable and controllable surface quality of the exit wire. The full-line tension zeroing protection triggered by the wire breakage signal and the maintenance of steam protection status solve the problems of copper wire scrapping and threading difficulties caused by tension loss and high-temperature oxidation at the moment of wire breakage, reducing wire breakage processing time and scrap rate, and improving equipment operational safety.

[0020] In one embodiment of the present invention, S1 includes: By adjusting the clamping force of the damping brush on the wire reel, the initial wire feeding resistance when the bare copper wire is released from the wire reel is set, and the basic wire feeding tension is obtained; wherein, the basic wire feeding tension is equal to the output resistance value corresponding to when the damping brush clamping force knob is adjusted to the process calibration scale. The traction speed of the auxiliary motor is preset by the basic wire tension and the frequency of the inverter output of the wire feeding auxiliary motor at the inlet of the annealing furnace to obtain the initial auxiliary traction speed value; wherein, the auxiliary traction speed value is equal to the real-time linear speed of the constant speed wheel multiplied by the positive deviation coefficient of the fixed linear speed between the constant speed wheel and the auxiliary motor. The frequency of the booster motor inverter is compensated by the booster traction speed value and the dynamic tension feedback signal of the copper wire during actual operation to obtain a stable pre-furnace tension. The compensation rule is as follows: when the dynamic tension feedback value is greater than the upper limit of the safe pre-furnace tension value, the inverter frequency is reduced by a fixed step size; when the dynamic tension feedback value is less than the lower limit of the safe pre-furnace tension value, the inverter frequency is increased by a fixed step size. After each compensation operation, a fixed time is waited before the next compensation judgment is performed. The stable pre-furnace tension is equal to the arithmetic mean of the dynamic tension feedback value when the dynamic tension feedback value is within the allowable range of the safe pre-furnace tension value for multiple consecutive sampling periods. By using the stable pre-furnace tension and the actual linear velocity signal at the constant speed wheel, the coordinated parameters of the wire feeding damping and the assist motor are adjusted and confirmed to obtain the safe pre-furnace tension value. The adjustment and confirmation method is to fix the damping brush clamping force at the process calibration scale and lock the upper limit of the assist motor torque to a fixed percentage of the rated torque. The safe pre-furnace tension value is equal to the current value of the stable pre-furnace tension after adjustment and confirmation.

[0021] The working principle and technical effect of the above technical solution are as follows: By adjusting the clamping force of the wire reel by the damping brush on the wire feeding frame, the initial wire feeding resistance when the bare copper wire is released from the reel is set, thus obtaining the basic wire feeding tension; then, by coordinating the basic wire feeding tension with the output frequency of the frequency converter of the wire feeding assist motor at the annealing furnace inlet, the traction speed of the assist motor is preset, thus obtaining the initial assist traction speed value; by comparing the assist traction speed value with the dynamic tension feedback signal of the copper wire during actual operation, the frequency of the frequency converter of the assist motor is compensated; finally, by comparing the compensated and stable tension before entering the furnace with the actual linear velocity signal at the constant speed wheel, the coordination parameters of the wire feeding damping and the assist motor are jointly adjusted and confirmed, thus obtaining the safe furnace entry tension value. Throughout the process, the dynamic tension feedback value is continuously compared with the upper and lower limits of the safe furnace entry tension value. When it exceeds the range, the frequency converter frequency is adjusted in the opposite direction by a fixed step size. After each adjustment, a fixed time is waited for the system to stabilize before the next judgment is made, forming a closed-loop adaptive adjustment.

[0022] This method addresses the tension fluctuations caused by changes in coil inertia, brush wear, and speed disturbances during copper wire release, which cannot be handled by single open-loop control through four stages: basic wire release tension setting, auxiliary traction speed pre-setting, dynamic tension feedback compensation, and coordinated parameter adjustment and confirmation. By vectorically superimposing the mechanical resistance of the damping brush and the electrical traction force of the auxiliary motor at the annealing furnace inlet, the furnace tension is kept stable within the allowable range of the process standard. Through successive comparisons and step-by-step adjustments of the dynamic tension feedback value with the upper and lower limits of the safe tension value, the adjustment lag problem caused by response overshoot or oscillation in traditional PID control is solved. The coordinated adjustment and confirmation stage fixes the damping brush clamping force to the process calibration scale and locks the upper limit of the auxiliary motor torque to a fixed percentage of the rated torque, solving the parameter mismatch problem between damping and auxiliary, and eliminating copper wire stretching or accumulation caused by improper coordination between the two.

[0023] In one embodiment of the present invention, the step of presetting the traction speed of the auxiliary motor by using the basic wire feeding tension and the frequency converter output frequency of the wire feeding auxiliary motor at the annealing furnace inlet to obtain an initial auxiliary traction speed value includes: The rated torque output range of the wire feeding assist motor at the annealing furnace inlet is matched and calculated using the basic wire tension value, and the initial output frequency of the frequency converter is set to obtain the basic speed of the assist motor; wherein, the initial output frequency of the frequency converter is equal to the current operating frequency of the fixed speed wheel frequency converter multiplied by the fixed linear velocity positive deviation coefficient; the basic speed of the assist motor is equal to the product of the initial output frequency of the frequency converter and the inherent speed conversion coefficient of the assist motor; The speed difference between the base speed of the power assist motor and the speed of the fixed speed wheel is calculated using the real-time linear velocity pulse signals at the base speed of the power assist motor and the speed of the fixed speed wheel to obtain the real-time speed deviation percentage; wherein, the real-time speed deviation percentage is equal to the percentage obtained by subtracting the speed of the fixed speed wheel from the speed of the power assist motor and dividing by the speed of the fixed speed wheel. The inverter frequency is adjusted stepwise by gradually approximating the real-time speed deviation percentage with a preset target deviation to obtain a precise assisted traction speed. The preset target deviation is fixed as a constant positive deviation percentage specified by the process. The stepwise approximation adjustment rule is as follows: when the real-time speed deviation percentage is lower than the lower limit of the preset target deviation, the inverter frequency is increased by a fixed step; when the real-time speed deviation percentage is higher than the upper limit of the preset target deviation, the inverter frequency is decreased by a fixed step. The interval between two adjacent adjustment operations is fixed. The precise assisted traction speed is equal to the linear velocity of the assist motor when the real-time speed deviation percentage first enters the bandwidth of the preset target deviation. The speed setpoint is verified online using the precise assisted traction speed and the assist motor current feedback signal to confirm that the motor is in a light-load traction state rather than an overload dragging state, thus obtaining the verified assisted traction speed value. The verification standard is that the assist motor operating current is within the light-load allowable current range of the rated current. If the assist motor operating current exceeds the upper limit of the light-load allowable current range, the inverter output frequency is reduced to the frequency corresponding to the alternative positive deviation value, and the step-by-step approximation adjustment is re-executed. The assisted traction speed value is equal to the current precise assisted traction speed value corresponding to when the assist motor operating current is within the light-load allowable current range.

[0024] The working principle and technical effect of the above technical solution are as follows: The rated torque output range of the wire feeding assist motor at the annealing furnace inlet is matched and calculated using the basic wire tension value. The initial output frequency of the frequency converter is obtained by multiplying the current operating frequency of the fixed-speed wheel frequency converter by a fixed linear speed positive deviation coefficient. Then, the speed difference between the basic speed of the assist motor and the real-time linear speed pulse signal at the fixed-speed wheel is calculated to obtain the real-time speed deviation percentage. The real-time speed deviation percentage is then gradually adjusted to approximate the preset target deviation. When the deviation is below the lower limit, a fixed step is added; when it is above the upper limit, a fixed step is removed. A fixed time interval is maintained between the two adjustments until the deviation enters the preset target deviation bandwidth, thus obtaining the precise assist traction speed. Finally, the precise assist traction speed is verified online using the assist motor current feedback signal to confirm that the motor operating current is within the light-load allowable range of the rated current. If it exceeds the upper limit, the frequency converter frequency is reduced to the alternative positive deviation value, and the approximation adjustment is re-executed to obtain the verified assist traction speed value.

[0025] This method addresses the problem of copper wire overstretching or accumulation caused by inaccurate traction speed setting of the assist motor through four steps: torque matching calculation, speed difference calculation, step-by-step approximation adjustment, and online current verification. By setting the initial speed using a fixed positive deviation coefficient multiplied by the speed-regulating wheel speed as a baseline, the assist motor always operates at a speed slightly higher than the speed-regulating wheel, resolving the sudden resistance change in the copper wire at the annealing furnace inlet due to speed difference. Step-by-step approximation adjustment of the real-time speed deviation percentage against the preset target deviation overcomes the inability of a single adjustment to overcome system inertia and response delay, allowing the actual speed deviation to quickly converge to within the allowable bandwidth. Online current verification confirms that the motor is in a light-load traction state rather than an overloaded dragging state, resolving the problem of motor overload or insufficient traction force caused by load estimation errors. If the current exceeds the light-load allowable range, it automatically switches to an alternative positive deviation value and readjusts, resolving the problem of fixed parameter failure under extreme conditions and ensuring that the motor always operates within the optimal operating range under different wire gauges and speeds.

[0026] In one embodiment of the present invention, S2 includes: The actual DV value under the current operating conditions is obtained by using the measured temperature values ​​of the safe furnace inlet tension value, the measured temperature values ​​of the annealing furnace inlet zone, the measured temperature values ​​of the annealing furnace middle zone, and the measured temperature values ​​of the annealing furnace outlet zone to calculate the product of the current line speed and the effective length of the annealing furnace in real time. The actual DV value is equal to the product of the current line speed and the effective tube length of the annealing furnace, and the effective tube length of the annealing furnace is a fixed value specified on the equipment nameplate. The actual DV value is compared with the recommended DV value range corresponding to the target line gauge to adjust the frequency of the fixed-speed wheel inverter by increasing or decreasing the speed to obtain the updated line speed. Specifically, if the actual DV value is less than the lower limit of the recommended DV value range, an increase operation is performed, with the increase step size being a fixed increment to the fixed-speed wheel inverter frequency. If the actual DV value is greater than the upper limit of the recommended DV value range, a decrease operation is performed, with the decrease step size being a fixed increment to the fixed-speed wheel inverter frequency. After a single increase or decrease operation, a fixed time is waited before the next comparison and determination. The updated line speed is equal to the line speed value corresponding to the current frequency of the fixed-speed wheel inverter after one increase or decrease operation. The elongation of the copper wire is sampled and tested using the samples taken after the updated line speed has stabilized to obtain the actual elongation. The criteria for determining the stable operation of the updated line speed are that the current frequency of the constant speed wheel inverter remains unchanged for multiple consecutive sampling cycles, and the fluctuations of the measured temperature values ​​in the annealing furnace inlet area, the annealing furnace middle section area, and the annealing furnace outlet area do not exceed their respective allowable bandwidths. The sampling and testing method is to select a specified number of samples after the stability determination is achieved, and perform elongation testing on each sample. The actual elongation is equal to the arithmetic mean of the test values ​​of all samples. By analyzing the deviation between the actual elongation and the standard required elongation, the annealing temperature setpoint or line speed is readjusted to obtain the annealing DV value range and the corresponding output elongation status information. The standard required elongation is the nominal elongation specified in the process standard. The deviation analysis method involves calculating the difference between the actual elongation and the standard required elongation. The readjustment rule is as follows: if the difference is positive and exceeds the upper tolerance zone, the temperature setpoint of each temperature zone in the annealing furnace is reduced by a fixed increment; if the difference is negative and exceeds the lower tolerance zone, the temperature setpoint of each temperature zone in the annealing furnace is increased by a fixed increment. If the direction of the difference does not change as expected after a stabilization waiting period following temperature adjustment, the frequency of the constant speed wheel inverter is adjusted by a fixed step size. The annealing DV value range is equal to the range of the current actual DV value after all adjustments are completed and stabilized. The output elongation status information is equal to the actual elongation in the stable state and the determination result of the relationship between the actual elongation and the standard required elongation tolerance zone.

[0027] The working principle and technical effect of the above technical solution are as follows: The actual DV value is obtained by calculating the product of the current line speed and the effective tube length of the annealing furnace in real time using the measured temperature values ​​of the safe furnace inlet tension value and the three temperature zones (inlet, middle, and outlet) of the annealing furnace. Then, the actual DV value is compared with the process-recommended DV value range corresponding to the target line gauge. If it is lower than the lower limit, the frequency of the constant-speed wheel inverter is increased by a fixed increment; if it is higher than the upper limit, it is decreased by a fixed increment. After each adjustment, a fixed time is waited before the next comparison is performed. Update the line speed; after the speed stabilizes, take a specified number of samples for elongation testing, and take the arithmetic mean of all test values ​​as the actual elongation; finally, perform deviation analysis by the difference between the actual elongation and the standard required elongation. If the difference exceeds the upper tolerance zone, reduce the temperature setting value of each temperature zone by a fixed setting. If it exceeds the lower tolerance zone, increase the temperature setting value by a fixed setting. If the direction of the difference does not change as expected after temperature adjustment, adjust the speed by a fixed step size to obtain the annealing DV value range and the corresponding elongation status information of the output line.

[0028] This method addresses the issue of over-annealing or under-annealing of copper wire caused by mismatch between the DV value and wire gauge during annealing through four steps: actual DV value calculation, speed adjustment, elongation detection, and readjustment of temperature or speed. By using the safe furnace tension value as a prerequisite for speed matching, it resolves the interference of tension fluctuations on speed stability, ensuring that speed adjustment is performed under controllable tension. Through successive comparisons and step-by-step adjustments between the actual DV value and the recommended process range, it resolves the issues of temperature field disturbances and system oscillations caused by single large-scale adjustments. By using elongation sampling detection results to reverse-correct temperature or speed setpoints, it addresses the problem that open-loop control relying solely on DV values ​​cannot handle batch differences in copper materials and furnace temperature drift. By determining the deviation direction and selecting a dual-channel strategy of prioritizing temperature adjustment and using speed as an alternative, it solves the problem of insufficient adjustment capability of a single adjustment method under extreme conditions, ensuring that the annealing quality remains stable within the target elongation tolerance zone.

[0029] In one embodiment of the present invention, the step of comparing the actual DV value with the process-recommended DV value range corresponding to the target line gauge, and adjusting the frequency of the constant-speed wheel inverter by increasing or decreasing the speed to obtain an updated line speed, includes: The deviation between the actual DV value and the recommended DV value range corresponding to the target wire gauge and paint type in the process parameter table is calculated to obtain the DV value deviation direction and magnitude. The recommended DV value range is the fixed lower limit to the fixed upper limit of the DV value at the intersection index of the current wire gauge and paint type in the process parameter table. The DV value deviation direction is either the actual DV value being greater than the upper limit of the recommended DV value range or the actual DV value being less than the lower limit of the recommended DV value range. The DV value deviation magnitude is equal to the absolute value of the difference between the actual DV value and the nearest limit of the recommended DV value range. By using the DV value deviation amplitude and the measured temperature value at the annealing furnace outlet area, the adjustment direction and adjustment step size of the constant speed wheel frequency converter are determined, thus obtaining the direction command and theoretical adjustment step size. The adjustment direction determination rule is as follows: the speed-up command or speed-down command is determined according to the DV value deviation direction. Then, the temperature deviation direction between the measured temperature value at the annealing furnace outlet area and the set temperature value at the annealing furnace outlet area is read. If the temperature deviation direction is the same as the DV value deviation direction, the adjustment step size is determined as a full step size; if the temperature deviation direction is opposite to the DV value deviation direction, the adjustment step size is determined as a half step size. The direction command is equal to the speed-up command or speed-down command finally determined according to the above rules. The theoretical adjustment step size is equal to the full step size or half step size finally determined according to the above rules. By adjusting the theoretical step size and the current speed settings of the circulating fan and the exhaust fan, the frequency of the constant-speed wheel inverter is incremented or decremented. After each operation, the measured temperature value at the annealing furnace outlet area is allowed to stabilize again to obtain the intermediate linear velocity. The current speed settings of the circulating fan and the exhaust fan are fixed to the standard operating speed values ​​specified by the process. The increment or decrement operation is performed by increasing or decreasing the current frequency of the constant-speed wheel inverter by one step according to the direction command and the theoretical adjustment step size. The criterion for determining the stabilization of the measured temperature value at the annealing furnace outlet area is that the fluctuation of the measured temperature value at the annealing furnace outlet area does not exceed the allowable bandwidth for multiple consecutive sampling periods. The intermediate linear velocity is equal to the linear velocity value corresponding to the current frequency of the constant-speed wheel inverter after the measured temperature value at the annealing furnace outlet area has stabilized again. The intermediate line speed is synchronously compared with the measured gloss level and color difference grade of the copper wire surface at the annealing furnace outlet to confirm abnormalities and obtain the updated line speed. The synchronous comparison criteria are that the copper wire surface color difference grade is not greater than the adjacent color level on the standard color card, and the measured gloss level is not less than the minimum allowable gloss value specified by the process. If the copper wire surface color difference grade is greater than the adjacent color level on the standard color card or the measured gloss level is less than the minimum allowable gloss value specified by the process, it is determined to be abnormal. The frequency of the constant speed wheel inverter is then adjusted back to the previous valid value before this adjustment, and the line speed corresponding to that frequency is used as the intermediate line speed for re-comparison. The updated line speed is equal to the final intermediate line speed value after passing both the color difference grade and gloss measurement criteria.

[0030] The working principle and technical effect of the above technical solution are as follows: The deviation is calculated by cross-indexing the actual DV value with the recommended DV value range of the target wire gauge and paint type in the process parameter table to obtain the direction and magnitude of the DV value deviation. Then, the adjustment direction and step size of the constant-speed wheel inverter frequency are determined by combining the deviation magnitude with the measured temperature value of the annealing furnace outlet area: first, the speed is increased or decreased according to the DV value deviation direction; then, correction is made according to the temperature deviation direction between the measured temperature value of the outlet area and the set value. If the directions are the same, a full step adjustment is made; if the directions are opposite, a half step adjustment is made. The frequency of the constant-speed wheel inverter is increased or decreased according to the determined direction command and step size. After each operation, the outlet area temperature is allowed to stabilize again to obtain the intermediate line speed. Finally, the intermediate line speed is synchronously compared with the measured value of the gloss of the outlet copper wire surface and the color difference grade. If both are qualified, the line speed is updated; otherwise, it reverts to the previous valid value and the comparison is re-executed.

[0031] This method addresses the repetitive oscillations caused by neglecting actual furnace temperature and copper wire surface quality feedback during DV value adjustment through four steps: DV value deviation calculation, temperature correction direction command determination, step-by-step frequency adjustment, and dual verification of gloss and color difference. By introducing measured temperature values ​​from the annealing furnace exit zone to correct the adjustment direction in the same or opposite direction, it solves the problem of neglecting the coupling effect between DV value adjustment and temperature changes, avoiding a vicious cycle of speed increase leading to temperature decrease and speed decrease leading to temperature increase. The adaptive switching strategy between full and half step sizes solves the problem of exacerbating temperature deviation when the temperature deviation direction is unfavorable with a single fixed step size. Synchronous comparison and verification of intermediate line speed with gloss and color difference levels solves the problem of not being able to perceive the actual surface condition of the copper wire by relying solely on electrical signal parameters. When gloss or color difference exceeds the standard, it automatically reverts to the previous valid value, solving the problem of invalid iteration under abnormal conditions and ensuring that the updated line speed meets both DV value and surface quality requirements.

[0032] In one embodiment of the present invention, S3 includes: The data from the liquid level sensor in the water seal tank is read using the elongation rate status information and the current production speed signal. The opening and closing status of the float valve in the water supply tank is then checked to obtain the water seal sealing status information. The opening and closing status check standard is that when the liquid level sensor reading reaches the set high limit water level of the water seal tank, the float valve in the water supply tank must be in the fully closed position, and when the liquid level sensor reading reaches the set low limit water level of the water seal tank, the float valve in the water supply tank must be in the fully open position. If the above correspondence is not met, the float valve is judged to be in an abnormal state. The water seal sealing status information is equal to the effective sealing determination when the liquid level sensor reading is between the set high limit water level of the water seal tank and the set low limit water level of the water seal tank, and the float valve status check shows no abnormality. The timing of deionized water replacement in the water supply tank is controlled by combining the water seal status information with the conductivity and chloride ion concentration measurements from the online water quality analyzer. The operation of the circulating filtration system is then confirmed to obtain clean and protective water information. Specifically, the deionized water replacement timing control rule is to trigger a water replacement command when the conductivity measurement value exceeds the maximum allowable conductivity value specified by the process or the chloride ion concentration measurement value exceeds the maximum allowable chloride ion concentration value specified by the process. When both the conductivity measurement value and the chloride ion concentration measurement value are not greater than the maximum allowable conductivity value specified by the process, the current water quality is maintained without water replacement. The circulating filtration system operation confirmation standard is that the circulating filtration system's operating status signal is "running" and the flow meter reading is between the lower and upper limits of the process-required flow rate. The clean and protective water information is equal to the circuit breaker judgment result where the conductivity measurement value is not greater than the maximum allowable conductivity value specified by the process, the chloride ion concentration measurement value is not greater than the maximum allowable chloride ion concentration value specified by the process, and the circulating filtration system operation confirmation shows no abnormalities. By combining the clean water protection information, actual production speed signal, and wire diameter specifications, the start-up temperature threshold, stop temperature threshold, and set temperature value of the water seal tank heater are set to obtain a reasonable water temperature and steam generation. Specifically, the start-up temperature threshold of the water seal tank heater is fixed as the process target temperature value minus the lower limit of the allowable fluctuation bandwidth; the stop temperature threshold is fixed as the process target temperature value plus the upper limit of the allowable fluctuation bandwidth; and the set temperature value is fixed as the process target temperature value. The heater starts when the measured temperature of the water seal tank is lower than the start-up temperature threshold and stops when the measured temperature of the water seal tank is higher than the stop temperature threshold. The reasonable water temperature is equal to the continuous stable state where the measured temperature of the water seal tank is within the process target temperature value ± the allowable fluctuation bandwidth. The steam generation is equal to the state where the water seal tank continuously generates saturated steam when the measured temperature of the water seal tank reaches the reasonable water temperature. The vortex air pump drying device behind the water outlet is activated in conjunction with the reasonable water temperature and the steam generation. The operating status and air pressure of the drying fan are confirmed to obtain the qualified annealing output quality. The linkage activation rule is to start the drying device after a fixed delay after the determination that the reasonable water temperature is reached and the steam generation is continuously stable. The standard for confirming the operating status of the drying fan is that the operating frequency of the drying fan is equal to the process set frequency value. The standard for confirming the air pressure is that the air pressure sensor reading is not less than the minimum air pressure value required by the process. The qualified annealing output quality is equal to the wire breakage protection judgment result that the actual elongation is within the standard elongation tolerance zone, the copper wire surface color difference grade is not greater than the adjacent color level of the standard color card, and the measured value of the copper wire surface gloss is not less than the minimum allowable gloss value specified by the process.

[0033] The working principle and technical effect of the above technical solution are as follows: The water seal tank level sensor data is read by the elongation status information of the output line and the current production speed signal, and the opening and closing status of the float valve of the water supply tank is checked to obtain the water seal sealing status information; then, the water seal sealing status information is used in conjunction with the conductivity and chloride ion concentration measurements of the online water quality analyzer to control the timing of deionized water replacement and confirm the operation of the circulating filtration system to obtain clean protective water information; the clean protective water information is used in conjunction with the actual production speed and wire diameter specifications to set the start-up temperature threshold, stop temperature threshold, and set temperature value of the water seal tank heater to obtain a reasonable water temperature and steam generation; finally, the reasonable water temperature and steam generation are linked to start the vortex air pump drying device behind the water outlet, and the operating frequency and air pressure of the drying fan are confirmed to obtain qualified annealing output quality.

[0034] This method addresses the oxidation and surface contamination of annealed copper wires caused by water seal failure through four steps: liquid level float verification, water conductivity control, heating temperature threshold setting, and dryer linkage startup. By correlating the liquid level sensor with the float valve's opening and closing status, it resolves water seal interruption caused by float valve jamming or response delay, ensuring the liquid level remains within the effective sealing range. Real-time online monitoring and replacement triggering of conductivity and chloride ion concentration address the issue of deionized water losing its protective capability due to impurity accumulation and increased conductivity over long-term use, ensuring water quality consistently meets process requirements. Setting heater start and stop thresholds and maintaining stable steam generation solves the problems of insufficient steam protection due to excessively low water temperature and energy waste due to excessively high water temperature, ensuring continuous saturated steam generation in the water seal tank to form an effective gas seal. The linkage logic of delayed startup of the dryer after the water temperature reaches the standard and steam stabilizes resolves the issues of premature start-up leading to steam protection failure or delayed start-up leading to water carryover at the outlet.

[0035] In one embodiment of the present invention, the step of reading the liquid level sensor data in the water seal tank and verifying the opening and closing status of the float valve of the water supply tank through the outgoing line elongation status information and the current production speed signal to obtain water seal sealing status information includes: The minimum safe water level threshold of the water seal tank is determined by the outgoing line elongation status information and the current production speed signal, and the real-time detection data of the liquid level sensor is periodically read to obtain the current dynamic change trend of the water level; wherein, the minimum safe water level threshold of the water seal tank is the minimum allowable water level value corresponding to the current production speed in the process standard; the reading period of the real-time detection data of the liquid level sensor is fixed to the standard sampling interval set by the system; the current dynamic change trend of the water level is equal to the time series of the water level values ​​and its monotonic change direction within multiple consecutive sampling periods; By correlating and comparing the current dynamic water level change trend with the opening and closing status signal of the float valve in the water supply tank, it is determined whether there is an abnormality in the float valve and a real-time diagnostic result is obtained. The correlation comparison rule is as follows: when the water level continuously rises and reaches the set high limit water level of the water seal tank, the float valve's opening and closing status signal must switch to the fully closed position within a specified response time; when the water level continuously falls and reaches the set low limit water level of the water seal tank, the float valve's opening and closing status signal must switch to the fully open position within a specified response time. If the float valve's opening and closing status signal fails to complete the corresponding switch within the specified response time, it is determined to be a response delay fault. If the water level has exceeded the set high limit water level or the set low limit water level of the water seal tank but the float valve's opening and closing status signal has not switched, it is determined to be a jamming fault. The real-time diagnostic result is equal to one of three states: no abnormality, response delay fault, or jamming fault. Based on the real-time diagnostic results, when the water level reaches the sum of the minimum safe water level threshold and the fixed safety margin of the water seal tank, an advance water replenishment command is issued to the water replenishment pump or the water supply solenoid valve to obtain the water level recovery curve and the stable water level value after water replenishment; wherein, the advance water replenishment command is a water replenishment pump start command or a command to open the water supply solenoid valve to a fixed opening degree; the water level recovery curve is equal to the trajectory of water level change over time from the moment the advance water replenishment command is issued until the water level reaches the target constant water level value and stabilizes; the stable water level value after water replenishment is equal to the arithmetic mean of the water level when the fluctuation of the water level value at the end of the water level recovery curve does not exceed the allowable bandwidth for multiple consecutive sampling periods; By analyzing the deviation between the stable water level after water replenishment and the target constant water level, and combining this with the results of bubble escape determination and negative pressure air intake determination at the furnace tube outlet, the flow rate of the water seal circulation pump is adjusted to obtain water seal sealing status information. The target constant water level is the operating water level specified by the process. The deviation is equal to the stable water level after water replenishment minus the target constant water level. The bubble escape determination rule is that a seal failure is determined when the bubble sensor detection value exceeds the maximum allowable bubble generation specified by the process. The negative pressure air intake determination rule is based on the furnace tube outlet... When the reading of the negative pressure sensor is less than the minimum allowable negative pressure value specified in the process, it is determined to be a seal failure; the flow regulation rule of the water seal circulation pump is that when the deviation value is positive, the frequency of the water seal circulation pump frequency converter is reduced by a fixed proportional coefficient, and when the deviation value is negative, the frequency of the water seal circulation pump frequency converter is increased by a fixed proportional coefficient; the water seal sealing status information is equal to the deviation value between the stable water level value after water replenishment and the target constant water level value being within the steady-state fluctuation range specified in the process, and the bubble escape determination result is not a failure, and the negative pressure air intake determination result is not a failure, and the line breakage protection determination result is not a failure.

[0036] The working principle and technical effect of the above technical solution are as follows: the minimum safe water level threshold of the water seal tank is determined by the elongation status information of the outlet line and the current production speed signal, and the real-time data of the liquid level sensor is read at a fixed sampling period to obtain the current dynamic change trend of the water level; then, the correlation comparison between the water level change trend and the opening and closing status signal of the float valve is used to determine whether the float valve is stuck or has a response delay fault, and obtain the real-time diagnostic results; when the water level reaches the sum of the minimum safe water level threshold and the fixed safety margin, a water replenishment command is issued in advance to obtain the water level recovery curve and the stable water level value after water replenishment; finally, the deviation between the stable water level value after water replenishment and the target constant water level value, combined with the judgment results of the escape of air bubbles from the furnace tube outlet and the negative pressure intake of air, is used to adjust the flow rate of the water seal circulation pump to obtain reliable water seal sealing status information.

[0037] This method addresses the issues of delayed water seal tank level control and undetected seal failures through four stages: water level trend monitoring, float valve fault diagnosis, pre-emptive water replenishment triggering, and flow deviation adjustment. By correlating the dynamic water level trend with the float valve status, it solves the problem of subtle float valve jamming or response delays being difficult to detect in their early stages, enabling timely diagnosis and differentiation between jamming and delay faults before they accumulate. By triggering the water replenishment command before the water level drops to the minimum safe threshold, it solves the problem of water level falling below the safety line due to delayed water replenishment in traditional low-level triggering methods, ensuring that the water level remains above the minimum safe threshold during recovery. By combining the deviation between the stable water level after replenishment and the target water level with two independent sealing judgment results—bubble escape and negative pressure suction—the method reversely adjusts the circulating pump flow rate, solving the air seal failure problem caused by water level fluctuations and ensuring the water seal remains reliable throughout the dynamic adjustment process.

[0038] In one embodiment of the present invention, S4 includes: The position sensor and wire breakage detection switch of the tension swing arm at the take-up device are monitored for normal operation based on the qualified annealed wire output quality to obtain a wire breakage sensing signal; wherein, the monitoring and acquisition cycle of the position sensor and wire breakage detection switch is fixed to the standard acquisition interval set by the system; the wire breakage sensing signal is equal to the signal triggered when the wire breakage detection switch is in the open state and the angle value of the position sensor exceeds the normal operating angle range. The system responds instantly to the stop command issued by the PLC controller via the broken wire sensing signal, stopping the operation of the take-up motor and the constant speed wheel at the corresponding take-up head, and issuing a command to decelerate the inlet assist motor to zero, thus obtaining tension zero-state information. The response delay of the PLC controller's stop command is fixed to the maximum allowable response delay time of the system; the deceleration slope of the inlet assist motor to zero is fixed to the standard deceleration rate value specified in the process; the tension zero-state information is equal to the confirmation result that the take-up motor has stopped operating, the constant speed wheel has stopped operating, the inlet assist motor speed is zero, and the overall tension detection value is zero. The tension zeroing status information is used to issue a hold command to the annealing furnace electric heating tube and water seal heater to maintain the current output value, while maintaining the current operating state of the drying device and obtaining protection status information during the wire breakage period. Specifically, the hold command for the annealing furnace electric heating tube to maintain the current output value is that the output power of each temperature zone of the annealing furnace is locked to the measured output power value of the last sampling cycle before the wire breakage signal is triggered, with the allowable fluctuation range limited to a fixed percentage bandwidth of the locked value. The hold command for the water seal heater to maintain the current output value is that the output power of the water seal heater is locked to the measured output power value of the last sampling cycle before the wire breakage signal is triggered. The command for the drying device to maintain the current operating state is that the operating frequency of the drying fan is locked to the measured operating frequency value of the last sampling cycle before the wire breakage signal is triggered. By combining the protection status information during the wire breakage period with the reset operation confirmation signal after the operator completes the wire threading, a command is issued to the take-up motor and the inlet auxiliary motor to restart synchronously according to the set parameters, thereby obtaining the wire breakage protection judgment result. The reset operation confirmation signal is a confirmation signal generated by the system after the reset button on the operation panel is continuously pressed for a specified duration. The acceleration curve of the restart command is a linear rise to a fixed rise time at each of its set frequencies. The wire breakage protection judgment result is equal to the comprehensive confirmation result of the take-up motor starting at the set take-up frequency, the inlet auxiliary motor starting at the set auxiliary frequency, the constant speed wheel starting at the set constant speed frequency, the output power of the annealing furnace electric heating tube returning to the automatic adjustment mode, the output power of the water seal heater returning to the automatic adjustment mode, and the operating frequency of the drying device returning to the process set frequency.

[0039] The working principle and technical effect of the above technical solution are as follows: The position sensor of the tension swing arm and the wire breakage detection switch at the take-up device are periodically monitored based on the qualified annealing wire output quality to obtain a wire breakage sensing signal. Then, the wire breakage sensing signal triggers a stop command from the PLC controller, stopping the take-up motor and constant speed wheel with a fixed response delay, and decelerating the inlet auxiliary motor to zero with a fixed deceleration slope, obtaining tension zero-state information. Based on the tension zero-state information, commands are sent to the electric heating tubes and water seal heaters in each temperature zone of the annealing furnace to maintain the current output value, while simultaneously locking the operating frequency of the drying fan at the current value, obtaining protection status information during the wire breakage period. Finally, based on the protection status information during the wire breakage period and the confirmation signal from the operator after completing the reset operation, a command is sent to the take-up motor and the inlet auxiliary motor to start synchronously with a linear acceleration curve, obtaining the wire breakage protection judgment result.

[0040] This method addresses the issues of copper wire oxidation in the high-temperature furnace tube during a wire breakage and the efficiency of re-threading after the breakage treatment through four stages: dual monitoring by a position sensor and a wire breakage switch, graded deceleration shutdown, locked heating power, and linear acceleration restart. By using dual judgment of the wire breakage detection switch status and the tension swing arm angle value, it overcomes the problem of false or missed triggers caused by interference in single wire breakage detection methods, improving the reliability of wire breakage detection. By using an assisted motor to decelerate to zero at a fixed deceleration slope rather than an abrupt stop, it solves the problem of copper wire breaking into multiple segments due to inertial stretching inside the furnace tube due to a sudden stop, reducing the difficulty of threading. By locking the current output values ​​of the annealing furnace electric heating tube, water seal heater, and drying device after shutdown, it solves the problem of prolonged preheating required for restarting due to temperature drops during wire breakage treatment, while maintaining a protective steam atmosphere inside the furnace tube. By using linear acceleration rather than a step-like restart for synchronous restart, it solves the problem of copper wire breaking at the joint or sudden tension changes due to sudden acceleration, ensuring a smooth and controllable transition from a wire breakage state to normal production.

[0041] In one embodiment of the present invention, the step of issuing a hold command to the electric heating tube and water seal heater of the annealing furnace to maintain the current output value through the tension zeroing state information, while maintaining the current operating state of the drying device, and obtaining protection state information during the wire breakage period, includes: The measured temperature values ​​of the annealing furnace inlet area, middle section area, and outlet area are latched using the tension zeroing state information. A forced command is then sent to the solid-state relays of the electric heating tubes in each temperature zone of the annealing furnace to maintain the current output power. Simultaneously, the integral and derivative output values ​​of the PID controller in the temperature control module are both set to zero, thus obtaining information on the constant furnace temperature. The forced command content is the measured output percentage of the electric heating tubes in the annealing furnace inlet area, locked at the measured output percentage value of the last sampling cycle before the disconnection signal is triggered. The output percentage of the electric heating tubes in the middle section of the furnace is locked at the measured output percentage value of the last sampling period before the disconnection signal is triggered; the output percentage of the electric heating tubes in the annealing furnace outlet section is locked at the measured output percentage value of the last sampling period before the disconnection signal is triggered; the allowable fluctuation range of each locked value is limited to a fixed percentage bandwidth; the furnace temperature constant maintenance status information is equal to the confirmation result that the measured temperature values ​​of the annealing furnace inlet section, the middle section section, and the outlet section are all locked near their respective measured values ​​before the disconnection signal is triggered and the fluctuation does not exceed the allowable bandwidth. By maintaining the constant furnace temperature, a lock command is issued to the output power of the water seal heater, and the steam flow meter reading is read to obtain the information on the continuous effectiveness of the steam protective atmosphere. The lock command for the output power of the water seal heater is the measured output percentage value of the water seal heater in the last sampling cycle before the disconnection signal is triggered. The confirmation criterion for the continuous effectiveness of the steam protective atmosphere is that the steam flow meter reading is greater than or equal to the flow rate corresponding to the minimum steam generation specified by the process. The continuous effective status information of the steam protective atmosphere is used to issue a command to the vortex pump of the drying device to maintain the current operating frequency, and the readings of the hot air curtain outlet temperature sensor and the wind speed sensor are read to obtain the air seal barrier status information. The command to maintain the current operating frequency of the vortex pump is to lock the operating frequency of the vortex pump to the measured operating frequency value of the last sampling cycle before the disconnection signal is triggered, and the allowable deviation range is limited to a fixed percentage bandwidth. The confirmation criteria for the air seal barrier status information are that the hot air curtain outlet temperature sensor reading is greater than or equal to the minimum allowable hot air curtain temperature value specified by the process and the wind speed sensor reading is greater than or equal to the minimum allowable hot air curtain wind speed value specified by the process. The protection status information during the line break is obtained by comprehensively determining the validity of the furnace temperature constant state information, the continuous effectiveness of the steam protective atmosphere state information, and the gas seal barrier state information, and repeatedly verifying the continuous effectiveness of the three at a fixed detection cycle during the operator's handling of the line break. The repeated verification rule within the fixed detection cycle is to read the measured temperature values ​​of the annealing furnace inlet area, the annealing furnace middle section area, and the annealing furnace outlet area, as well as the steam flow meter reading, the hot air curtain outlet temperature sensor reading, and the wind speed sensor reading, once every fixed observation cycle. Each reading value is compared with its corresponding threshold. When all reading values ​​meet the corresponding threshold requirements, it is determined that the triple protection is simultaneously effective. The protection status information during the line break is equal to the cumulative confirmation result of the simultaneous effectiveness of the triple protection in each fixed detection cycle during the entire line break handling period.

[0042] The working principle and technical effect of the above technical solution are as follows: The measured temperature values ​​of the annealing furnace inlet, middle section, and outlet zones are latched by the tension zero-state information. A forced command is sent to the solid-state relays of the electric heating tubes in each temperature zone to maintain the current output power. Simultaneously, the integral and derivative output values ​​of the PID controller are set to zero, thus obtaining information on the constant furnace temperature. Then, a lock command is sent to the output power of the water seal heater based on the constant furnace temperature information, and the steam flow meter reading is continuously read to confirm that the steam generation meets the standard, thus obtaining information on the continuous effectiveness of the steam protective atmosphere. A command is sent to the vortex pump to maintain the current operating frequency based on the continuous effectiveness of the steam protective atmosphere information, and the hot air curtain outlet temperature and wind speed readings are continuously read to confirm the integrity of the hot air curtain, thus obtaining information on the gas seal barrier status. Finally, through a comprehensive judgment that the constant furnace temperature, the continuous effectiveness of the steam protective atmosphere, and the integrity of the gas seal barrier are all effective, and the continuous effectiveness of these three factors is repeatedly verified according to a fixed detection cycle during the disconnection process, the protection status information during the disconnection period is obtained.

[0043] This method addresses the issue of copper wire oxidation and discoloration within the high-temperature furnace tubes during wire breakage by employing four key steps: furnace temperature locking, continuous steam flow monitoring, thermal curtain integrity verification, and triple protection cycle verification. By locking the output percentage of the electric heating tubes in each temperature zone and setting the integral and derivative terms of the PID controller to zero, it resolves the problem of furnace temperature drop caused by the temperature control module automatically reducing power due to thermocouple reading changes during wire breakage, ensuring the furnace temperature remains near the annealing temperature throughout the entire process. Locking the power of the water seal heater and continuously verifying the steam flow meter readings resolves the issue of weakened or interrupted steam protection due to water temperature drops, ensuring a constant steam seal at the furnace tube outlet. Locking the vortex pump operating frequency and verifying both the thermal curtain outlet temperature and wind speed resolves the problem of the furnace tube inlet seal disappearing when the drying device stops during wire breakage, thus establishing a gas seal barrier at both the furnace tube inlet and outlet. By repeatedly verifying and accumulating effective judgments of the three protection states within a fixed detection cycle, the problem that a single judgment cannot cover the entire wire breakage handling time is solved, ensuring that the triple protection is always effective simultaneously during the entire shutdown period, and ensuring that the copper wire does not oxidize during long periods of shutdown in the high-temperature furnace tube.

[0044] According to one embodiment of the present invention, the system includes: The safe entry analysis module is used to pre-set and dynamically compensate the tension of the bare copper wire entering the annealing furnace at the inlet by coordinating the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor to obtain the safe entry tension value. The safe entry tension value is equal to the net tension value after the wire feeding resistance corresponding to the clamping force of the wire feeding damping brush and the traction force of the inlet assist motor are superimposed at the annealing furnace inlet. The allowable range of the net tension value is from the lower limit to the upper limit of the tension range corresponding to the current wire gauge in the process standard. The matching and adjustment module is used to adjust the line speed in the annealing furnace in real time by using the safe furnace tension value and the measured temperature feedback of the three temperature control zones of the annealing furnace to obtain the annealing DV value range and the corresponding line elongation status information; wherein, the annealing DV value range is from the lower limit of the DV value to the upper limit of the DV value corresponding to the current line gauge in the process parameter table; The synchronous control module is used to adjust the deionized water level, water quality, and heating temperature in the water seal tank in conjunction with the elongation status information and the current production speed signal, and to synchronously control the operation status of the drying device after the water outlet to obtain qualified annealed wire quality; wherein, the qualified annealed wire quality is the judgment result that the actual elongation is within the target elongation tolerance zone and the color difference grade of the copper wire surface is not greater than the adjacent color level of the standard color card; The collaborative control module is used to perform emergency zero-tension protection for the entire production line based on the qualified annealing line output quality and the breakage detection signal at the take-up device, while maintaining the steam protection state of the annealing furnace, and obtaining the breakage protection judgment result. The breakage protection judgment result is a confirmation that after the breakage detection signal is triggered, all drive motors on the entire production line are stopped, the output power of the annealing furnace electric heating tube is locked at the measured value before the breakage, the set temperature of the water seal heater is locked at the set value before the breakage, and the operating frequency of the drying device is locked at the operating value before the breakage.

[0045] The working principle and technical effects of the above technical solution are as follows: This invention uses the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor to pre-set and dynamically compensate the tension of the bare copper wire at the inlet of the annealing furnace, thereby obtaining a safe inlet tension value; through the feedback of the safe inlet tension value and the measured temperature of the three temperature control zones, the wire speed in the annealing furnace is matched and adjusted in real time to obtain the optimal annealing DV value range and the corresponding wire elongation status information; through the wire elongation status information and the current production speed signal, the deionized water level, water quality and heating temperature in the water seal tank are adjusted in linkage, and the operating status of the drying device after the water outlet is synchronously controlled to obtain qualified annealed wire output quality; through the qualified annealed wire output quality and the wire breakage detection signal at the take-up device, the tension of the entire line is reset to zero in an emergency, while maintaining the steam protection state of the annealing furnace, and obtaining the wire breakage protection judgment result.

[0046] By linking tension presetting, DV value matching, water seal linkage adjustment, and wire breakage emergency protection into a complete process coordinated control chain, the problem of response lag and matching mismatch caused by independent adjustment of process parameters during annealing is solved, achieving full-line coordination from the front-end furnace inlet tension to the back-end wire take-up quality. A dynamic compensation mechanism solves the tension drift problem caused by thermal expansion and speed fluctuations in the annealing furnace, keeping the furnace inlet tension stable within the allowable range. Real-time matching of wire walking speed based on measured temperature feedback solves the problem of DV value deviation from the process window, ensuring precise correspondence between the annealing degree and the copper wire specifications. Linked adjustment of water level, water quality, and water temperature, along with synchronous control of the drying device, solves the problems of water seal failure and water oxidation on the exit wire, ensuring stable and controllable surface quality of the exit wire. The full-line tension zeroing protection triggered by the wire breakage signal and the maintenance of steam protection status solve the problems of copper wire scrapping and threading difficulties caused by tension loss and high-temperature oxidation at the moment of wire breakage, reducing wire breakage processing time and scrap rate, and improving equipment operational safety.

[0047] Example 2

[0048] This embodiment further defines the identification of abnormal sources, selection of control objects, adjustment sequence, adjustment range, and stabilization waiting conditions when multiple operating parameters deviate simultaneously or continuously.

[0049] The annealing tension co-control method for enameled wire production described in this embodiment includes steps S1 to S5.

[0050] S1. Obtain the safe furnace loading tension value; S2. Obtain the elongation status information of the lead wire; S3. Obtain qualified annealing output quality; S4. Obtain the line breakage protection determination result; S5. Identify the dominant and accompanying abnormal parameters and formulate phased coordinated adjustment instructions.

[0051] Step S5 is executed under the basic control conditions formed in steps S1 to S4, including steps S51 to S53.

[0052] S51. Based on parameter deviation, direction of change, sequence of occurrence, and temperature propagation relationship, obtain the anomaly attribution results for each candidate control object.

[0053] The line speed, annealing temperature, and safe feed tension were selected as candidate control parameters. The controller synchronously reads the safe feed tension, annealing furnace inlet temperature, middle section temperature, outlet temperature, line speed, circulating fan operating status, and exhaust fan operating status according to a unified acquisition cycle, and compares them with the stable reference range corresponding to the current line gauge and paint type.

[0054] For the safe feed tension, the degree of deviation is determined based on the difference between the real-time tension value and the reference safe feed tension value, the direction of the difference change, the duration of the tension change, and the slope of the tension change. For the three temperature zones, the degree of deviation for each zone is determined based on the difference between the measured temperature and the corresponding set temperature in the inlet, middle, and outlet zones, the direction of temperature rise / fall, and the rate of temperature change. For the travel speed, the degree of deviation is determined based on the difference between the current travel speed of the constant speed wheel and the target travel speed, and its duration.

[0055] For the circulating fan's operating status, based on the current speed, operating current, and inlet temperature changes of the circulating fan, determine whether the furnace thermal circulation has weakened, strengthened, or become unstable. For the exhaust fan's operating status, based on the current speed and furnace negative pressure changes of the exhaust fan, determine whether the exhaust suction effect has strengthened, weakened, or fluctuated.

[0056] After obtaining the degree of deviation for each parameter, the moment when each parameter first exceeds the allowable deviation range is further recorded, and a sequence of parameter anomalies is formed according to time. If the traveling speed increases, followed by a decrease in the inlet zone temperature, middle zone temperature, and outlet zone temperature, while the operating status of the circulating fan and exhaust fan remains stable, then the current temperature deviation is considered to be highly correlated with the change in traveling speed. If the operating status of the circulating fan changes, followed by anomalies in the inlet and middle zone temperatures, and a similar deviation in the outlet zone temperature after a certain period, then the current temperature anomaly is considered to be highly correlated with changes in circulating heat exchange. If the exhaust fan speed or furnace negative pressure changes, and the outlet zone temperature deviates first, followed by changes in the middle zone temperature, then the current temperature anomaly is considered to be highly correlated with changes in exhaust suction.

[0057] Simultaneously, based on the copper wire running direction and the heat transfer relationship between the three temperature control zones of the annealing furnace, the propagation sequence of temperature anomalies is determined. Temperature changes in the inlet zone should affect the middle and outlet zones before they do; temperature changes in the middle zone should primarily affect the middle and outlet zones; changes in furnace negative pressure caused by changes in the exhaust fan status usually first produce a significant temperature response in the outlet zone. If the actual temperature change sequence is consistent with the above propagation relationship, the attribution degree of the corresponding anomaly source is increased; if the actual change sequence is significantly inconsistent, the attribution degree of the corresponding anomaly source is decreased.

[0058] The safe charging tension is determined by considering the load current of the inlet assist motor, the deviation between the assist traction speed and the constant speed wheel speed, and the time relationship of dynamic tension changes. If the load current of the inlet assist motor increases, the assist traction speed decreases relative to the constant speed wheel speed, and subsequently the safe charging tension increases, then insufficient inlet assist is considered highly correlated with the current tension anomaly. If the inlet assist motor operates stably, but the safe charging tension changes accordingly after the constant speed wheel speed changes, then the tension deviation is considered an accompanying anomaly caused by changes in line speed.

[0059] The controller generates anomaly attribution results for linear speed, annealing temperature, and safe furnace tension based on the degree of deviation, direction of change, sequence of occurrence, and temperature propagation matching of each parameter. A higher degree of anomaly attribution indicates that the current parameter combination more closely matches the operating characteristics of the corresponding candidate control object when an anomaly occurs.

[0060] S52. Based on the adjustable margin, response lag, historical convergence degree, and additional quality risk, obtain the effective control results of each candidate control object.

[0061] After the anomaly attribution results are generated in step S51, it is further determined whether each candidate control object is suitable for immediate adjustment under the current operating conditions.

[0062] For the travel speed, read the remaining adjustment range between the current inverter frequency of the constant speed wheel and the upper and lower limits of the allowable frequency to determine the adjustable margin of the travel speed. Based on the records of the most recent travel speed adjustments, calculate the time required for the inlet temperature to start responding, the middle temperature to start responding, and the outlet temperature to stabilize again after the constant speed wheel frequency change to determine the furnace temperature response lag that may be caused by the current travel speed adjustment.

[0063] Furnace temperature response lag refers to the time delay required from the moment the frequency of the constant speed wheel inverter changes (i.e., the linear speed begins to change) until the measured temperature of each temperature zone (inlet zone, middle zone, and outlet zone) of the annealing furnace begins to show observable changes and eventually stabilizes again.

[0064] If the actual DV value deviation and the wire elongation deviation gradually decrease after each adjustment of the wire speed, then the wire speed adjustment is considered to have a good historical adjustment effect. If the actual DV value deviation decreases while the wire elongation deviation increases, it indicates that although the wire speed adjustment improved the actual DV value, it failed to improve the actual annealing quality of the copper wire, thus reducing the effectiveness of the wire speed control.

[0065] For the annealing temperature, the remaining adjustment range between the current temperature setpoints of the annealing furnace inlet zone, middle zone, and outlet zone and their respective upper and lower allowable limits is read to determine the adjustable margin of each temperature zone. Combining the propagation time of the three temperature zones after each temperature adjustment, the degree of temperature overshoot in the outlet zone, the actual DV value change, and the change in line elongation, it is determined whether adjusting the annealing temperature can achieve stable convergence of the annealing state.

[0066] If a temperature zone is already close to the upper or lower limit of the process allowable limit, the effectiveness of further adjustments to that temperature zone will be reduced. If furnace temperature oscillations occur after adjusting multiple temperature zones simultaneously in previous adjustments, the simultaneous change of setpoints for multiple temperature zones will be restricted in this adjustment.

[0067] To determine the safe loading tension, read the current inverter frequency of the inlet auxiliary motor, the deviation between the auxiliary traction speed and the constant speed wheel speed, the load current of the inlet auxiliary motor, and the remaining adjustment space of the safe loading tension relative to the allowable range.

[0068] Meanwhile, based on the current temperatures of the three temperature zones of the annealing furnace, the degree of softening of the copper wire in the high-temperature zone, and the direction of change in the safe loading tension, the potential additional impact of tension adjustment on the actual elongation of the copper wire is assessed. When the annealing furnace temperature is high and the safe loading tension is already too high, further increasing the traction of the inlet assist motor may cause additional stretching of the copper wire, thus increasing the additional quality risk of adjusting the safe loading tension and limiting its adjustment range.

[0069] The controller integrates the degree of abnormality of each candidate control object, the adjustable margin, the response lag, the convergence degree of the actual DV value in each cycle, the convergence degree of the elongation rate in each cycle, and the possible additional quality risks to form effective results for line speed control, effective results for annealing temperature control, and effective results for safe furnace tension control.

[0070] Candidate regulators with a high degree of anomaly attribution but insufficient adjustability margin, excessive response lag, or high additional quality risk are not directly designated as priority regulators. Candidate regulators with a high degree of anomaly attribution, sufficient adjustability margin, stable historical adjustment effects, and low additional quality risk have a high degree of regulatory effectiveness.

[0071] S53. Determine the dominant control target, accompanying control targets, and control process based on the anomaly attribution results and the effective control results. The abnormal attribution results of line speed, annealing temperature and safe furnace tension are integrated with the effective control results to form the control priority order of the three candidate control objects.

[0072] During the integration process, the consistency between the degree of anomaly attribution and the effectiveness of regulation is considered simultaneously. If a candidate regulatory object is strongly correlated with the current anomaly, but currently lacks sufficient adjustable margin or poses a high risk of additional quality, its regulatory priority is reduced. If both the degree of anomaly attribution and the effectiveness of regulation of a candidate regulatory object are high, its regulatory priority is increased.

[0073] The candidate control object with the highest control priority is determined as the primary control object, and the candidate control object with the second highest control priority is determined as the secondary control object. Within a control cycle, the primary control object is adjusted first, while the secondary control object remains in its current state. Once the primary control object has completed its adjustment and reached the corresponding stability waiting condition, steps S51 to S53 are repeated. Subsequent adjustments to the secondary control object are only implemented if the actual DV value deviation or the outgoing line elongation deviation has not yet met the convergence requirements.

[0074] When the driving speed is determined as the primary control target, the adjustment range for each instance is determined based on the degree of driving speed deviation, the actual DV value deviation, and the current adjustable margin of the constant speed wheel. For small deviations, an adjustment of 0.5% to 1% of the current driving speed is used; for medium deviations, an adjustment of 1% to 2% of the current driving speed is used; for large deviations, an adjustment of 2% to 3% of the current driving speed is used. The single adjustment range shall not exceed 3% of the current vehicle speed specified in Example 1.

[0075] When adjusting the constant-speed wheel frequency, the original proportional relationship between the inlet assist motor traction speed and the constant-speed wheel speed should be maintained simultaneously to avoid sudden changes in the safe furnace tension caused by changes in the constant-speed wheel speed. After adjustment, the temperature of the three temperature zones should be continuously monitored. When the outlet temperature has produced a response consistent with the direction of this speed adjustment, and the temperature deviations of the inlet, middle, and outlet zones remain within the allowable range for multiple consecutive sampling cycles, the line speed adjustment is considered complete and stable.

[0076] When the annealing temperature is determined as the primary control target, the temperature zone to be adjusted first is determined based on the order of occurrence and direction of propagation of the temperature deviations in the three temperature zones. When the inlet zone temperature deviates and causes the middle and outlet zones to change in the same direction in sequence, the inlet zone is adjusted first; when the middle zone deviates alone while the inlet zone remains stable, the middle zone is adjusted first; when the outlet zone temperature deviation occurs simultaneously with changes in the operating status of the exhaust fan, first confirm whether the exhaust fan and furnace negative pressure are normal, and then determine whether to adjust the outlet zone temperature.

[0077] The adjustment range of the annealing temperature per step is determined based on the degree of temperature deviation. For small deviations, adjust by one to two degrees Celsius per step; for medium deviations, adjust by two to three degrees Celsius per step; for large deviations, adjust by three to five degrees Celsius per step. The adjusted temperature setting should remain within the allowable range for the target wire gauge and paint type.

[0078] Only one temperature zone is adjusted within one adjustment cycle. After the temperature change in that zone is transmitted to the subsequent temperature zones and the outlet temperature stabilizes again, it is then determined whether the next temperature zone needs to be adjusted, thus avoiding furnace temperature oscillation caused by simultaneous changes in the setpoints of three temperature zones.

[0079] When the safe furnace tension is determined as the primary control target, fine-tuning is performed through the frequency converter of the inlet assist motor, and the assist traction speed is kept within the range of 94% to 96% of the constant speed wheel speed as described in Example 1.

[0080] When the safety feed tension deviation is small, the single frequency adjustment of the inlet booster motor inverter should not exceed 0.5% of the rated frequency; when the deviation is in the medium range, the single adjustment should be 0.5% to 1% of the rated frequency; when the deviation is large, the single adjustment should be 1% to 2% of the rated frequency.

[0081] Smaller: The dynamic tension feedback value exceeds the upper limit of the safe furnace tension value by no more than one-third of the allowable bandwidth width, or is lower than the lower limit by no more than one-third of the allowable bandwidth width.

[0082] Medium range: The dynamic tension feedback value exceeds the upper limit of the safe furnace tension value by more than one-third but not more than two-thirds of the allowable bandwidth, or is lower than the lower limit by more than one-third but not more than two-thirds of the allowable bandwidth.

[0083] Larger: The dynamic tension feedback value exceeds the upper limit of the safe furnace tension value by more than two-thirds of the allowable bandwidth, or the value below the lower limit exceeds two-thirds of the allowable bandwidth.

[0084] After adjustment, continuously read the dynamic tension feedback signal, the load current of the inlet assist motor, and the speed signal of the constant speed wheel. When the safe furnace tension remains stable for five consecutive times, the inlet assist motor is in a light-load traction state, and the deviation between the assist traction speed and the constant speed wheel speed is within the preset range, the safe furnace tension adjustment is considered complete.

[0085] If the three temperature zones of the annealing furnace are at a high temperature, and the increased safety tension may cause additional elongation of the high-temperature copper wire, then the increase in the frequency of the inlet assist motor should be limited, and the annealing condition should be improved by adjusting the line speed or annealing temperature.

[0086] When the actual DV value has entered the recommended range, but the elongation at the outlet line still does not meet the standard requirements, the current adjustment is not considered complete. The controller re-analyzes the changes in safe feed tension, the temperature distribution of the three temperature zones, and the furnace temperature response status after speed adjustment. If the safe feed tension remains excessively high under high temperature conditions, the classification of the abnormal safe feed tension is increased; if the three temperature zones have not yet reached thermal equilibrium, the stabilization waiting time is extended; if the temperature distribution of the three temperature zones is uneven, the priority order of annealing temperature control is re-determined.

[0087] If the operating status of the circulating fan or exhaust fan exceeds the allowable range of the equipment, suspend compensatory adjustments to the line speed, annealing temperature, and safe furnace feed tension, and first restore the circulating fan or exhaust fan to normal operation. After the fan's operating status stabilizes and a thermal equilibrium cycle is completed, repeat steps S51 to S53 to avoid using process parameter adjustments to mask the abnormality of the circulating fan or exhaust fan itself.

[0088] One specific operating state of this embodiment is as follows: the constant-speed wheel speed increases, and then the temperature in the annealing furnace inlet zone, middle zone, and outlet zone decreases sequentially according to the copper wire running direction. The safe furnace tension only increases slightly, and the operating state of the circulating fan and exhaust fan remains stable. Based on the parameter change sequence and the propagation relationship of the three temperature zones, the controller determines the running speed as the dominant abnormal parameter. Since the constant-speed wheel still has a speed reduction margin, and each speed reduction adjustment can synchronously reduce the deviation of the actual DV value and the deviation of the outgoing wire elongation, the running speed is determined as the dominant control object.

[0089] The controller first reduces the frequency of the constant speed wheel and simultaneously adjusts the operating speed of the inlet assist motor to maintain the original speed ratio between the inlet assist motor and the constant speed wheel. Before the outlet temperature has fully responded, the temperature settings for the three temperature zones and the safe inlet tension are not adjusted. After the three temperature zones stabilize again, the actual DV value and the elongation of the output wire are checked, and it is reassessed whether the accompanying control device needs to be activated.

[0090] Another specific operating state of this embodiment is as follows: the actual DV value has entered the recommended range, but the elongation rate of the output wire remains high. The safe loading tension has increased before the elongation rate abnormality occurs, and the load current of the inlet auxiliary motor increases simultaneously, while the temperature of the three temperature zones and the traveling wire speed remain stable. Based on this, the controller determines the safe loading tension as the dominant abnormal parameter and gradually reduces the safe loading tension by slightly decreasing the frequency of the inlet auxiliary motor inverter. After the dynamic tension stabilizes, the elongation rate of the annealed output wire continues to be monitored until both the actual DV value and the elongation rate of the output wire enter the corresponding allowable range.

[0091] The working principle and technical effect of the above technical solution are as follows: Based on the control of safe furnace tension, three-stage temperature zone, actual DV value and outgoing line elongation rate established in Example 1, this embodiment further uses the deviation degree, change direction, occurrence sequence and temperature propagation relationship of each parameter to identify the source of abnormality, and combines the adjustable margin, response lag, historical convergence degree and additional quality risk of the candidate control object to determine the actual control sequence.

[0092] By separating the identification of anomaly sources from the judgment of current control conditions, parameters that are highly correlated but not currently suitable for adjustment can be avoided from being directly used as the primary control object. By adjusting only one primary control object within an adjustment cycle and re-judging the accompanying control objects after the corresponding physical stability waiting period, furnace temperature oscillations caused by simultaneous changes in line speed, annealing temperature, and safe feed tension can be reduced.

[0093] By using the synchronous convergence of the actual DV value deviation and the wire elongation deviation as the adjustment completion condition, the state where the actual DV value is within the recommended range but the annealed wire elongation is still unqualified can be identified. By incorporating the additional impact of the safe furnace tension on the actual elongation of high-temperature copper wire into the selection of the control object, the risk of copper wire being subjected to additional stretching and unexpected thinning under high-temperature softening conditions can be reduced.

[0094] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for coordinated control of annealing tension in enameled wire production, characterized in that, The method includes: S1. By coordinating the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor, the tension of the bare copper wire entering the annealing furnace is preset and dynamically compensated to obtain a safe inlet tension value. S2. By using the safe furnace tension value and the actual temperature feedback of the three temperature control zones of the annealing furnace, the line speed in the annealing furnace is matched and adjusted in real time to obtain the annealing DV value range and the corresponding line elongation status information. S3. Based on the elongation status information of the output line and the current production speed signal, the deionized water level, water quality and heating temperature in the water seal tank are adjusted in a coordinated manner, and the operation status of the drying device behind the water outlet is controlled synchronously to obtain qualified annealing output quality. S4. Based on the qualified annealing output quality and the wire breakage detection signal at the take-up device, the tension of the entire wire is reset to zero in an emergency, while maintaining the steam protection state of the annealing furnace, and the wire breakage protection judgment result is obtained.

2. The annealing tension co-control method for enameled wire production according to claim 1, characterized in that, S1 includes: By adjusting the clamping force of the wire reel on the damping brush on the wire reel, the initial wire feeding resistance when the bare copper wire is released from the wire reel is set, and the basic wire feeding tension is obtained. The traction speed of the auxiliary motor is preset by using the basic wire tension and the frequency of the inverter output of the wire feeding auxiliary motor at the inlet of the annealing furnace to obtain the initial auxiliary traction speed value. By using the traction speed value and the dynamic tension feedback signal of the copper wire during actual operation, the frequency of the traction motor inverter is compensated to obtain a stable tension before entering the furnace. By using the stable pre-furnace tension and the actual linear velocity signal at the constant speed wheel, the coordinated parameters of the wire feeding damping and the assist motor are adjusted and confirmed to obtain the safe pre-furnace tension value.

3. The annealing tension coordinated control method for enameled wire production according to claim 2, characterized in that, The step of presetting the traction speed of the auxiliary motor by using the basic wire tension and the frequency converter output frequency of the wire feeding auxiliary motor at the annealing furnace inlet to obtain an initial auxiliary traction speed value includes: The rated torque output range of the wire feeding assist motor at the annealing furnace inlet is matched and calculated by the basic wire feeding tension value, and the initial output frequency of the frequency converter is set to obtain the basic speed of the assist motor. The speed difference between the base speed of the power assist motor and the speed of the fixed speed wheel is calculated using the real-time linear velocity pulse signals at the base speed of the power assist motor and the speed of the fixed speed wheel to obtain the real-time speed deviation percentage. By gradually adjusting the real-time speed deviation percentage against the preset target deviation, the frequency of the inverter is adjusted in steps to obtain a precise traction speed. The speed setpoint is verified online by using the precise assist traction speed and assist motor current feedback signal to confirm that the motor is in a light-load traction state rather than an overload dragging state, and the verified assist traction speed value is obtained.

4. The annealing tension coordinated control method for enameled wire production according to claim 1, characterized in that, S2 includes: The actual DV value under the current operating conditions is obtained by using the measured temperature values ​​of the safe furnace inlet tension value, the measured temperature values ​​of the annealing furnace inlet area, the annealing furnace middle section area, and the annealing furnace outlet area to calculate the product of the current line speed and the effective length of the annealing furnace in real time. By comparing the actual DV value with the process-recommended DV value range corresponding to the target line gauge, the frequency of the constant speed wheel frequency converter is adjusted to increase or decrease the speed to obtain the updated line speed. The elongation of the copper wire is sampled and tested using the outgoing samples after the updated line speed has stabilized to obtain the actual elongation. By analyzing the deviation between the actual elongation and the standard required elongation, the annealing temperature setting or the line speed is readjusted to obtain the annealing DV value range and the corresponding elongation status information of the output line.

5. The annealing tension coordinated control method for enameled wire production according to claim 4, characterized in that, The step of comparing the actual DV value with the recommended DV value range corresponding to the target line gauge, and adjusting the frequency of the constant speed wheel inverter to increase or decrease the speed to obtain the updated line speed includes: The deviation between the actual DV value and the recommended DV value range corresponding to the target gauge and paint type in the process parameter table is calculated to obtain the direction and magnitude of the DV value deviation. By using the deviation of the DV value and the measured temperature value of the annealing furnace outlet area, the adjustment direction and adjustment step size of the frequency of the constant speed wheel inverter are determined, and the direction command and theoretical adjustment step size are obtained. By adjusting the step size and the current speed setting of the circulating fan and the current speed setting of the exhaust fan according to the theory, the frequency of the constant speed wheel inverter is increased or decreased, and after each operation, the measured temperature value of the annealing furnace outlet area is waited to stabilize again to obtain the intermediate linear speed. By synchronously comparing the intermediate line speed with the measured value of the surface gloss of the copper wire at the annealing furnace outlet and the color difference grade of the copper wire surface, abnormal phenomena are confirmed, and the updated line speed is obtained.

6. The annealing tension coordinated control method for enameled wire production according to claim 1, characterized in that, S3 includes: By using the elongation status information of the output line and the current production speed signal, the liquid level sensor data in the water seal tank is read, and the opening and closing status of the float valve of the water supply tank is checked to obtain the water seal sealing status information. By using the water seal status information and the conductivity and chloride ion concentration measurements from the online water quality analyzer, the timing of deionized water replacement in the water supply tank is controlled, and the operation of the circulating filtration system is confirmed to obtain clean and protective water information. By combining the clean water information with the actual production speed signal and wire diameter specifications, the start-up temperature threshold, stop temperature threshold, and set temperature value of the water seal tank heater are set to obtain a reasonable water temperature and steam generation. The vortex air pump drying device behind the water outlet is started in conjunction with the reasonable water temperature and the amount of steam generated, and the operating status and air pressure of the drying fan are confirmed to obtain the qualified annealing output quality.

7. The annealing tension coordinated control method for enameled wire production according to claim 6, characterized in that, The process involves reading data from the liquid level sensor in the water seal tank using the outgoing line elongation status information and the current production speed signal, and verifying the opening and closing status of the float valve in the water supply tank to obtain water seal sealing status information, including: The minimum safe water level threshold of the water seal tank is determined by the outgoing line elongation status information and the current production speed signal, and the real-time detection data of the liquid level sensor is periodically read to obtain the current dynamic change trend of the water level. By correlating and comparing the current dynamic change trend of the water level with the opening and closing status signal of the float valve in the water supply tank, it is determined whether there is any abnormality in the float valve and real-time diagnostic results are obtained. Based on the real-time diagnostic results, when the water level reaches the sum of the minimum safe water level threshold and the fixed safety margin of the water seal tank, an advance water replenishment command is issued to the water replenishment pump or water supply solenoid valve to obtain the water level recovery curve and the stable water level value after water replenishment. By analyzing the deviation between the stable water level after water replenishment and the target constant water level, and combining the results of bubble escape at the furnace tube outlet and negative pressure air intake, the flow rate of the water seal circulation pump is adjusted to obtain water seal sealing status information.

8. The annealing tension coordinated control method for enameled wire production according to claim 1, characterized in that, S4 includes: The position sensor of the tension swing arm and the wire breakage detection switch at the take-up device are monitored for normal operation by using the qualified annealed wire output quality to obtain the wire breakage sensing signal. The system responds instantly to the stop command issued by the PLC controller via the broken wire sensing signal, stops the operation of the take-up motor and the constant speed wheel at the corresponding take-up head, and issues a command to the inlet assist motor to decelerate to zero, thereby obtaining tension zero state information. The tension zeroing state information is used to send a hold command to the electric heating tube and water seal heater of the annealing furnace to maintain the current output value, while maintaining the current operating state of the drying device and obtaining the protection state information during the wire breakage. By using the protection status information during the wire breakage period and the confirmation signal of the reset operation after the operator completes the wire threading, a command is sent to the take-up motor and the inlet auxiliary motor to restart synchronously according to the set parameters, thereby obtaining the wire breakage protection judgment result.

9. The annealing tension coordinated control method for enameled wire production according to claim 8, characterized in that, The process involves issuing a hold command to the annealing furnace electric heating tube and water seal heater to maintain the current output value based on the tension zero-state information, while simultaneously maintaining the current operating state of the drying device and obtaining protection status information during the wire breakage period, including: The measured temperature values ​​of the annealing furnace inlet area, the annealing furnace middle section area, and the annealing furnace outlet area are latched by the tension zero state information. A forced command to maintain the current output power is sent to the solid-state relays of the electric heating tubes in each temperature zone of the annealing furnace. At the same time, the integral term output value and the derivative term output value of the PID controller in the temperature control module are both set to zero to obtain the furnace temperature constant maintenance state information. By maintaining the constant furnace temperature, a lock command is issued to the output power of the water seal heater, and the steam flow meter reading is read to obtain the information on the continuous effectiveness of the steam protective atmosphere. The steam protective atmosphere status information is used to send a command to the vortex air pump of the drying device to maintain the current operating frequency, and the readings of the hot air curtain outlet temperature sensor and wind speed sensor are read to obtain the air seal barrier status information. The protection status information during the line break is obtained by comprehensively determining the validity of the furnace temperature constant state information, the steam protective atmosphere continuous effective state information, and the gas seal barrier state information, and by repeatedly verifying the continuous effectiveness of the three at a fixed detection cycle during the operator's handling of the line break.

10. An annealing tension coordinated control system for enameled wire production, characterized in that, The system includes: The safe entry analysis module is used to pre-set and dynamically compensate the tension of the bare copper wire entering the annealing furnace by coordinating the frequency conversion speed regulation of the wire feeding damping brush and the inlet assist motor, so as to obtain the safe entry tension value. The matching and adjustment module is used to adjust the line speed in the annealing furnace in real time by using the safe furnace tension value and the measured temperature feedback of the three temperature control zones of the annealing furnace to obtain the annealing DV value range and the corresponding line elongation status information. The synchronous control module is used to adjust the deionized water level, water quality and heating temperature in the water seal tank in conjunction with the elongation status information of the output line and the current production speed signal, and to synchronously control the operation status of the drying device behind the water outlet to obtain qualified annealing output quality. The collaborative control module is used to perform emergency zeroing protection for the tension of the entire line based on the qualified annealing output quality and the breakage detection signal at the take-up device, while maintaining the steam protection state of the annealing furnace and obtaining the breakage protection judgment result.

Images