An automatic transposition head debugging method and system based on adaptive gap compensation

Abstract

This invention discloses an automatic transposition head debugging method and system based on adaptive gap compensation, belonging to the field of automation control technology. The method includes acquiring conductor thickness, width, and number of conductors and disengaging the cam linkage; sequentially moving the transposition head to the positions for push finger replacement, single-row threading, double-row threading, and split-row dragging according to the debugging guide, while simultaneously matching the corresponding stop fingers; in the automatic measurement stage, generating preset target positions for each servo mechanism based on conductor parameters, calculating position errors based on actual positions, and automatically generating gap compensation values ​​and opening dimensions in the vertical and horizontal directions; controlling the servo mechanisms to position according to the target positions after superimposing compensation values, and adjusting the opening and closing distance of the pressure fingers and pressure plates; detecting that the number of conductor rows, spacing, and misalignment meet the transposition process conditions, and restoring normal production mode. This invention uses automatic generation of gap compensation values ​​combined with stop finger specification matching to automate the transposition head debugging, eliminating positioning deviations caused by mechanical gaps.

Description

Technical Field

[0001] This invention relates to the field of automation control technology, and in particular to an automatic switching head debugging method and system based on adaptive gap compensation. Background Technology

[0002] The transposition head is a core mechanical component in transformer winding manufacturing equipment, primarily used to exchange the spatial positions of multiple flat conductors. Modern industrial production demands increasingly stringent precision in the transposition process, requiring precise control of the coordinated movements of the spindle, pressure fingers, pressure plates, and multi-axis servo actuators during the transposition head's adjustment. The control system needs to accurately allocate and schedule the spatial coordinates of each mechanical component based on parameters such as conductor thickness, width, and number of conductors.

[0003] In related technologies, Chinese invention patent CN122261014A discloses a method and system for correcting positioning errors on a semiconductor packaging equipment stage, comprising: fixing a fixture with a preset feature array on the bearing surface of the stage and performing compatibility verification; collecting physical position data of at least one set of key reference features on the fixture in the current motion coordinate system, constructing a dynamic motion model, calculating the pose parameters of the fixture relative to the motion axis of the stage, generating a dynamic predicted coordinate point set based on the pose parameters; driving a visual imaging system to traverse the path planned by the predicted coordinate point set, and performing a dynamic prediction on each predicted coordinate point set. At each node, the corresponding fixture features are located through multi-level adaptive visual search. After multiple sampling and dynamic stability verification, the pixel domain deviation is converted into motion control domain error and synthesized with the current predicted coordinates to generate the original physical coordinate dataset. Anomaly identification and reconstruction are performed on the original physical coordinate dataset to obtain cleaned physical position data. An error mapping relationship is established based on the cleaned physical position data, and a compensation model is constructed. The compensation model is dynamically loaded and consistency verification is performed. If the health assessment is passed, the data is deemed valid and real-time compensation is activated. The coordinates are corrected in real time based on the local neighborhood, and operational fault safety monitoring is performed.

[0004] However, the aforementioned existing technical solutions have the following technical defects: Firstly, they cannot automatically analyze positional errors and generate gap compensation values, causing mechanical transmission backlash to interfere with the positioning accuracy of the transposition head. Secondly, they lack closed-loop control of the debugging wizard and servo actuator, making it impossible to achieve automated and precise positioning of the transposition head's multi-station wire threading action. Thirdly, they cannot adaptively generate the opening dimensions of the pressure fingers and pressure plates based on conductor specification parameters, requiring repeated manual adjustments, which can easily lead to parameter setting deviations. Fourthly, they lack an automatic comparison mechanism between the conductor arrangement state and the transposition process conditions, failing to ensure a smooth transition from the debugging state to normal production mode. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides an automatic head-switching method and system based on adaptive gap compensation. By automatically generating gap compensation values ​​and combining them with the matching of stop finger specifications, the head-switching process can be automated, eliminating positioning deviations caused by mechanical gaps.

[0006] The above objectives can be achieved through the following approach: An automatic transposition head debugging method based on adaptive gap compensation includes: acquiring conductor thickness, width, and number parameters and disengaging the cam linkage; sequentially moving the transposition head to the positions of push finger replacement, single-row threading, double-row threading, and split-row dragging according to the debugging wizard, while matching the corresponding stop fingers; in the automatic measurement stage, generating preset target positions for each servo mechanism based on conductor parameters, calculating position errors based on actual positions, and automatically generating gap compensation values ​​and opening dimensions in the up-down and left-right directions; controlling the servo mechanism to position according to the target position after superimposing the compensation values, and adjusting the opening and closing distance of the pressure fingers and pressure plates; detecting that the number of conductor rows, spacing, and misalignment meet the transposition process conditions, and restoring normal production mode.

[0007] Optionally, the function of detecting the spindle zero position of the transposition head and the initial state of each servo actuator, obtaining the set conductor thickness, conductor width and conductor number parameters, and deactivating the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging starts includes: obtaining the spindle position data and verifying the spindle zero position; detecting whether each servo actuator is in a standby state that allows debugging; recording the set conductor thickness, conductor width and conductor number as reference parameters for subsequently generating the target position of the servo actuator, and cutting off the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle.

[0008] Optionally, the step of controlling the transposition head to move sequentially to the finger replacement position, single-row threading position, double-row threading position, and split-row and drag-wire position according to the guidance of the debugging wizard, wherein matching the corresponding specification of the finger stop according to the conductor width parameter includes: extracting the acquired conductor width parameter, selecting the finger stop corresponding to the size of the conductor width parameter; starting the debugging wizard, issuing the corresponding movement commands sequentially according to the preset debugging steps; controlling the transposition head to respond to the movement commands, and step-by-step positioning to the finger replacement position, single-row threading position, double-row threading position, and split-row and drag-wire position.

[0009] Optionally, the calculation of the position error of each servo actuator includes: extracting the current actual position and the preset target position corresponding to each servo actuator respectively; comparing the current actual position of each servo actuator with its corresponding preset target position and calculating the difference to obtain the absolute value of the deviation between the two; determining the direction of movement of the current actual position deviating from the preset target position, and generating a position error with direction attribute by combining the absolute value of the deviation.

[0010] Optionally, automatically generating clearance compensation values ​​and opening dimensions in the vertical and horizontal directions based on the position error includes: analyzing the position error according to the motion axis corresponding to each servo actuator, distinguishing it into vertical position error and horizontal position error; calling a preset clearance compensation algorithm model to convert the vertical and horizontal position errors into vertical and horizontal clearance compensation values ​​for eliminating mechanical transmission backlash; extracting the acquired conductor thickness and conductor width parameters, and superimposing the conductor thickness and conductor width parameters with the vertical and horizontal clearance compensation values ​​to generate an opening dimension that meets the requirements of the current conductor specification for threading and repositioning.

[0011] Optionally, controlling each servo actuator to complete positioning according to the target position after superimposing the gap compensation value, and adjusting the opening and closing distance of the pressure finger and pressure plate according to the opening size includes: superimposing the preset target position of each servo actuator with the corresponding gap compensation value to generate corrected absolute positioning coordinates for eliminating mechanical backlash; issuing motion commands containing the corrected absolute positioning coordinates to the drivers of each servo actuator to drive each servo actuator to move and accurately position to the corrected target position; converting the generated opening size into a stroke control signal for the pressure finger and pressure plate, and issuing it to the servo driver controlling the pressure finger and pressure plate; and adjusting the relative distance between the upper and lower pressure fingers and between the upper and lower pressure plates in response to the stroke control signal.

[0012] Optionally, the step of restoring normal production mode after detecting that the number of wire rows, the spacing between them, and the staggered state meet the preset transposition process conditions includes: acquiring the actual state feedback signal of the wire arrangement, parsing out the number of wire rows, the spacing between them, and the staggered state; comparing the number of wire rows, the spacing between them, and the staggered state with the transposition process conditions to determine whether the state meets the standard; if it meets the standard, saving the corrected target position after superimposing the gap compensation value of each servo actuator and the opening and closing distance of the pressure finger and the pressure plate as production parameters; re-establishing the synchronous linkage of the cam linkage mechanism between the pressure finger and the main shaft; exiting the debugging state, switching to normal production mode, and calling the production parameters for operation.

[0013] Optionally, the step of calling a preset clearance compensation algorithm model to convert the vertical and horizontal position errors into vertical and horizontal clearance compensation values ​​for eliminating mechanical transmission backlash includes: determining the reverse clearance direction in the mechanical transmission chain of each actuator based on the motion direction attribute of the position error; multiplying the absolute value of the deviation according to a preset compensation ratio coefficient based on the reverse clearance direction, and then adding it to the corresponding axial and mechanism reference compensation amount obtained from a preset clearance compensation database to obtain the preliminary compensation value for each axial direction; subjecting the preliminary compensation value to vertical and horizontal limit constraints, and outputting the constrained values ​​as the vertical and horizontal clearance compensation values, respectively.

[0014] Optionally, the method further includes: if the standard is not met, extracting the process deviation value between the actual state of the current wire arrangement and the transposition process conditions; determining whether the process deviation value exceeds a preset mechanical tolerance safety threshold; if it does not exceed the mechanical tolerance safety threshold, converting the process deviation value into a secondary compensation increment, updating and overwriting the gap compensation value of the corresponding servo actuator, and returning to execute control of each servo actuator according to the target position after superimposed compensation value; if it exceeds the mechanical tolerance safety threshold, determining that there is mechanical interference or excessive wear, triggering an abnormal diagnosis alarm signal, and controlling each servo actuator of the transposition head to enter a safety locking state.

[0015] Based on the same inventive concept, this invention also provides an automatic switching head debugging system based on adaptive gap compensation. The system includes: an initial state detection and parameter acquisition module, used to detect the spindle zero position and the initial state of each servo actuator of the switching head, acquire set conductor thickness, conductor width, and conductor number parameters, and release the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging starts; a debugging wizard guidance and switching head control module, used to control the switching head to sequentially move to the finger replacement position, single-row threading position, double-row threading position, and split-row and dragging position according to the debugging wizard guidance, wherein the corresponding specification of the finger stop is matched according to the conductor width parameter; and an automatic measurement and position error calculation module, used to calculate the position error based on the conductor thickness, conductor width, and conductor number parameters during the automatic measurement phase. The system generates preset target positions for each servo actuator based on width and conductor number parameters, acquires the current actual positions of the spindle, upper pressure finger, lower pressure finger, upper pressure plate, lower pressure plate, front left-right mechanism, rear left-right mechanism, and rear up-down mechanism, and calculates the position error of each servo actuator. A gap compensation value and opening size generation module automatically generates gap compensation values ​​and opening sizes for correction in the up-down and left-right directions based on the position errors. A positioning and spacing adjustment module controls each servo actuator to complete positioning according to the target position after superimposing the gap compensation values, and adjusts the opening and closing spacing of the pressure finger and pressure plate according to the opening size. A process condition detection and production mode recovery module restores normal production mode after detecting that the number of conductor columns, arrangement spacing, and misalignment status meet preset repositioning process conditions.

[0016] Compared with the prior art, the present invention has the following advantages: This invention eliminates the interference of mechanical transmission backlash on the positioning accuracy of the transposition head by automatically analyzing position errors and generating gap compensation values.

[0017] This invention utilizes a debugging wizard and closed-loop control of a servo actuator to achieve automated and precise positioning of the multi-station threading action of the transposition head.

[0018] This invention adaptively generates the opening dimensions of the pressure finger and pressure plate based on conductor specification parameters, avoiding parameter setting deviations caused by repeated manual trial and error.

[0019] This invention establishes an automatic comparison mechanism between the wire arrangement state and the transposition process conditions, ensuring a smooth transition of the equipment from the debugging state to the normal production mode.

[0020] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description, claims and drawings. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a flowchart illustrating an automatic head-switching debugging method based on adaptive gap compensation according to an embodiment of the present invention. Figure 2 This is a heatmap of the vertical opening size distribution generated by adaptive overlay in an embodiment of the present invention; Figure 3 This is a logic diagram for determining the process deviation value and mechanical tolerance safety in an embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of an automatic head switching debugging system based on adaptive gap compensation according to an embodiment of the present invention. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Reference Figure 1 One embodiment of the present invention proposes an automatic switching head debugging method based on adaptive gap compensation. By automatically generating gap compensation values ​​and combining them with the specification matching of the stop finger, the debugging of the switching head can be automated, eliminating the positioning deviation caused by mechanical gaps.

[0025] The method described in this embodiment specifically includes: S1. Detect the spindle zero position of the transposition head and the initial state of each servo actuator, obtain the set conductor thickness, conductor width and conductor number parameters, and release the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging and starting. Optionally, the function of detecting the spindle zero position of the transposition head and the initial state of each servo actuator, obtaining the set conductor thickness, conductor width, and conductor number parameters, and releasing the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging and startup includes: Acquire the spindle position data and verify the spindle zero position, and check whether each servo actuator is in a standby state that allows debugging; Record the set conductor thickness, conductor width, and number of conductors, and use them as reference parameters for generating the target position of the servo actuator. Also, cut off the synchronous linkage between the pressure finger and the spindle cam linkage mechanism.

[0026] Specifically, the spindle position data represents the current angle measurement value of the rotary axis, the spindle zero position represents the reference starting position of the rotary axis movement, verifying the spindle zero position requires calculating the spindle zero position deviation, the spindle zero position deviation represents the relative degree of the current position deviating from the reference position, each servo actuator represents the motor and transmission device that drive the mechanical parts to move, and the standby state represents the stationary state where the motor stops running and is ready to receive control commands.

[0027] Conductor thickness represents the height dimension of the conductor cross-section, conductor width represents the width dimension of the conductor cross-section, conductor number parameter represents the total number of conductors involved in the transposition process, reference parameter represents the basic data used to calculate the target coordinates, synchronous linkage function of the cam linkage mechanism between the cutting pressure finger and the spindle, pressure finger represents the mechanical actuator used to clamp the conductor, cam linkage mechanism represents the transmission device that realizes the mechanical action association through the cam profile, synchronous linkage function represents the characteristic that the pressure finger moves in a fixed proportion as the spindle rotates. The cutting synchronous linkage function is achieved by controlling the electromagnetic clutch to disengage the mechanical connection. The formula for calculating the spindle zero position deviation is: , in the formula Represents the spindle zero-position deviation, dimensionless; This represents the position data of the main axis, in degrees. This represents the preset zero point, in degrees, and is set to a fixed value of 0 based on actual measurements from 200 sets of industrial sensors. This represents the maximum permissible deviation angle, in degrees, and is based on the equipment's mechanical tolerances. The formula for calculating the reference volume in the reference parameters is: , in the formula This represents a reference volume, expressed in cubic millimeters. This represents the conductor thickness, measured in millimeters. This represents the conductor width, measured in millimeters. It represents the number of conductor elements and is dimensionless. The unit length coefficient is set to a fixed length based on 50 transposition process tests.

[0028] For example, obtain the position data of the spindle. It is 2 degrees. Preset zero point. The maximum permissible deviation angle is 0 degrees. The value is 5 degrees. Substitute the value into the formula to calculate the spindle zero-position deviation. This value meets the allowable deviation range of the equipment, thus completing the verification of the spindle zero position. Record the set conductor thickness. It is 2 mm wide. It is 5 mm. Conductor root count parameter. It is 10. Unit length coefficient. The value is 100 mm. Substitute the value into the formula to calculate the reference volume. The calculated reference volume is measured in cubic millimeters. This volume is used as a reference parameter for generating the target position of the servo actuator. The system then controls the electromagnetic clutch to disengage, cutting off the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle, ensuring that each servo actuator is in a standby state that allows for debugging.

[0029] S2. Following the guidance of the debugging wizard, control the switching head to move sequentially to the finger replacement position, single-row wire threading position, double-row wire threading position, and split-row and drag-wire position, wherein the corresponding specification of the blocking finger is matched according to the conductor width parameter. Optionally, guided by the debugging wizard, the switching head is controlled to sequentially move to the finger replacement position, the single-row threading position, the double-row threading position, and the split-row and drag-wire position, wherein matching the corresponding specification of the finger stop according to the conductor width parameter includes: Extract the acquired conductor width parameters and select the stop finger corresponding to the size of the conductor width parameters; Start the debugging wizard and issue the corresponding movement commands in sequence according to the preset debugging steps. The switching head is controlled to respond to the movement command and is positioned step by step to the push finger replacement position, single-row threading position, double-row threading position, and split-row and dragging position.

[0030] Specifically, the conductor width parameter represents the width of the conductor cross-section, and the stop finger represents the mechanical blocking component used to restrict the lateral movement of the conductor. The control program calculates the matching dimensions of the stop finger, thereby completing the selection of components of the corresponding specifications. The formula for calculating the matching dimensions of the stop finger is: , in the formula This represents the matching size of the stop finger piece, in millimeters; This represents the conductor width parameter, in millimeters. The representative process clearance is in millimeters and is set as a fixed value based on actual measurements of 100 threading processes.

[0031] The commissioning wizard represents an interactive control program that guides operators through the initial setup of the equipment. The commissioning step sequence represents the predetermined order in which the equipment performs actions during the commissioning phase. A movement command represents a digital control signal that controls the motor to move to the target coordinate. The underlying controller calculates the number of pulses for the movement command based on the target position, and uses this to drive the servo mechanism. The formula for calculating the number of pulses for the movement command is: , in the formula The number of pulses representing the movement command, dimensionless; This represents the distance the target has moved, in millimeters. This represents the lead screw pitch, measured in millimeters, and is based on the mechanical transmission parameters of the equipment. This represents the number of pulses per revolution of the motor, is dimensionless, and is based on the specifications of the servo motor encoder.

[0032] The transposition head represents the core mechanical assembly that performs the exchange of wire positions. The push-fin replacement position represents the spatial coordinates for easy operator installation and removal of the metal piece pushing the wire. The single-row threading position represents the spatial coordinates for guiding a single row of wires through the transposition mechanism. The double-row threading position represents the spatial coordinates for guiding two rows of wires through the transposition mechanism simultaneously. The split-row and drag-line position represents the spatial coordinates for dividing the wires into two rows and pulling them backward. After positioning is completed, the system calculates the positioning error to ensure that the mechanical components accurately reach the preset coordinates. The formula for calculating the positioning error is: , in the formula This represents the positioning error, expressed in millimeters. This represents the actual location reached, in millimeters.

[0033] For example, extract the acquired conductor width parameter. The clearance is 5 mm, with a pre-existing gap in the manufacturing process. The value is 1 mm. Substitute the value into the formula to calculate the matching size of the stop finger. The system selects the corresponding size of the stop finger based on the conductor width parameter (in millimeters). Start the commissioning wizard; the equipment prepares to move according to the preset commissioning steps. Set the target movement distance. The lead screw is 50 mm. It is 10 mm, and the number of pulses per motor revolution is... The value is 10000. Substitute this value into the formula to calculate the number of pulses for the movement command. The control system sequentially issues corresponding movement commands. The control switching head responds to these commands, positioning itself step-by-step to the finger replacement position, single-row threading position, double-row threading position, and split-row / dragging position. Sensors provide feedback on the actual position reached. The value is 50.02 mm. Substitute this value into the formula to calculate the positioning error. Millimeters. This positioning error data directly verifies the effectiveness of the transposition head in accurately reaching each designated position.

[0034] S3. In the automatic measurement stage, the preset target position of each servo actuator is generated according to the conductor thickness, conductor width and conductor number parameters, the current actual position of the spindle, upper pressure finger, lower pressure finger, upper pressure plate, lower pressure plate, front left and right mechanism, rear left and right mechanism and rear up and down mechanism is obtained, and the position error of each servo actuator is calculated. Optionally, the calculation of the position error of each servo actuator includes: Extract the current actual position and preset target position of each servo actuator; The current actual position of each servo actuator is compared with its corresponding preset target position, and the difference is calculated to obtain the absolute value of the deviation between the two. The direction of movement of the current actual position deviating from the preset target position is determined, and a position error with directional attributes is generated by combining the absolute value of the deviation.

[0035] Specifically, the automatic measurement phase represents the period during which the equipment autonomously acquires the spatial coordinates of each component using sensors. The preset target position represents the ideal coordinates that the mechanical component is expected to reach, calculated based on the conductor specifications. The formula for calculating the preset target position is: , in the formula This represents the preset target position, in millimeters. This represents the conductor thickness, measured in millimeters. This parameter represents the number of conductor elements and is dimensionless. The thickness arrangement coefficient is dimensionless and set to a fixed value based on actual measurements of 500 wiring processes. This represents the conductor width parameter, in millimeters. The width arrangement coefficient is dimensionless and is set to a fixed value based on actual measurements of 500 wiring processes.

[0036] The current actual position represents the real coordinates of the mechanical component as fed back by the sensor in real time. Each servo actuator specifically includes a spindle, upper pressure finger, lower pressure finger, upper pressure plate, lower pressure plate, front left and right mechanism, rear left and right mechanism, and rear up and down mechanism. The spindle represents the core shaft that drives the rotation of the shift head. The upper and lower pressure fingers represent the actuators that press the wires from the top and bottom. The upper and lower pressure plates represent the plate-shaped components that flatten the wire arrangement from the top and bottom. The front left and right mechanism and the rear left and right mechanism represent the actuators that control the horizontal movement of the wires in the horizontal direction. The rear up and down mechanism represents the actuators that control the vertical movement of the wires in the rear direction.

[0037] The current actual position of each servo actuator is compared with its corresponding preset target position, and the difference is calculated. The control program calculates the absolute value of the deviation between the two. The absolute value of the deviation represents the non-negative value of the difference between the actual coordinates and the ideal coordinates. The formula for calculating the absolute value of the deviation is: , in the formula Represents the absolute value of the deviation, in millimeters; This represents the current actual location, in millimeters.

[0038] The direction of motion represents the spatial vector pointing from the current position to the target position of the mechanical component. Position error represents a comprehensive spatial correction vector that includes both the magnitude of the deviation and the direction of motion. The formula for calculating position error is: , in the formula Represents positional error, in millimeters; Represents the direction of motion, dimensionless. When the current actual position is less than the preset target position, it is set to a positive value of 1 based on the positive direction of the coordinate system. When the current actual position is greater than the preset target position, it is set to a negative value of -1 based on the negative direction of the coordinate system.

[0039] For example, during the automatic measurement phase, the system obtains the conductor thickness. 2 mm, conductor root parameter The conductor width parameter is 10. It is 5 mm. Thickness arrangement factor The width arrangement coefficient is 0.5. The value is 1.2. Substitute the value into the formula to calculate the preset target position of the upper pressure finger. Millimeters. The system extracts the current actual position of the pressure finger. The value is 14 mm. Substitute the value into the formula to calculate the absolute value of the deviation. Millimeters. Since the current actual position of 14 millimeters is smaller than the preset target position of 16 millimeters, the system determines the direction of movement. The value is positive 1. Substitute the value into the formula to calculate the position error. Millimeters. This calculation process directly verifies the effectiveness of generating position errors with directional attributes by combining the absolute value of the deviation. Based on this, the system completes the error calculation for each servo actuator, including the spindle, upper pressure finger, lower pressure finger, upper pressure plate, lower pressure plate, front left and right mechanism, rear left and right mechanism, and rear up and down mechanism.

[0040] S4. Based on the position error, automatically generate gap compensation values ​​and opening dimensions in the vertical and horizontal directions for correction; Optionally, the step of automatically generating clearance compensation values ​​and opening dimensions in the vertical and horizontal directions for correction based on the position error includes: The position error is analyzed according to the motion axis corresponding to each servo actuator, and is divided into position error in the vertical direction and position error in the horizontal direction. The preset gap compensation algorithm model is invoked to convert the position errors in the vertical and horizontal directions into gap compensation values ​​in the vertical and horizontal directions, respectively, for eliminating mechanical transmission backlash. Extract the acquired conductor thickness and conductor width parameters, and then superimpose the conductor thickness and conductor width parameters with the gap compensation values ​​in the vertical direction and the horizontal direction, respectively, to generate an opening size that meets the requirements of the current conductor specification for threading and transposition.

[0041] Specifically, the control system analyzes the position error according to the motion axis corresponding to each servo actuator. The motion axis represents the reference coordinate axis direction for the mechanical component to perform linear movement in space. The system extracts coefficients along the axis to distinguish between position errors in the vertical direction and position errors in the horizontal direction. The vertical position error represents the spatial correction vector generated along a direction perpendicular to the horizontal plane, while the horizontal position error represents the spatial correction vector generated along a direction parallel to the horizontal plane and perpendicular to the direction of the guide wire. The formula for calculating the vertical position error is: , in the formula This represents the positional error in the vertical direction, expressed in millimeters. Represents positional error, in millimeters; This represents the extraction coefficient for the vertical axis, is dimensionless, and is set to a fixed value of 1 when analyzing vertical motion mechanisms based on the equipment coordinate system; otherwise, it is set to a fixed value of 0. The formula for calculating the position error in the left and right directions is: , in the formula This represents the positional error in the left-right direction, expressed in millimeters. This represents the extraction coefficient for the left and right axes. It is dimensionless and is set to a fixed value of 1 when analyzing horizontal motion mechanisms based on the equipment coordinate system; otherwise, it is set to a fixed value of 0.

[0042] The backlash compensation algorithm model represents the mathematical calculation rules used to calculate the backlash value of gears or lead screws in reverse rotation to compensate for the backlash. Mechanical transmission backlash represents the idle distance that exists when mechanical transmission components switch between forward and reverse motion. The backlash compensation value in the vertical direction represents the compensation distance used to correct mechanical backlash in the vertical direction, and the backlash compensation value in the horizontal direction represents the compensation distance used to correct mechanical backlash in the horizontal direction. The formula for calculating the backlash compensation value in the vertical direction is: , in the formula This represents the clearance compensation value in the vertical direction, in millimeters. This represents the vertical compensation coefficient, is dimensionless, and is set to a fixed value based on 100 transmission tests. This represents the inherent backlash in the vertical direction, measured in millimeters, and is set based on the equipment's factory mechanical measurement data. The formula for calculating the backlash compensation value in the horizontal direction is: , in the formula This represents the clearance compensation value in the left and right directions, in millimeters. This represents the compensation coefficient in the left and right directions. It is dimensionless and set to a fixed value based on 100 transmission tests. This represents the inherent back clearance in the left-right direction, measured in millimeters, and is set based on the equipment's factory mechanical measurement data.

[0043] The opening dimension represents the distance that the pressure fingers or pressure plates need to maintain during operation. Specifically, it includes the vertical opening dimension and the horizontal opening dimension. The formula for calculating the vertical opening dimension is: , in the formula This represents the opening size in the vertical direction, in millimeters. This represents the conductor thickness, measured in millimeters. This represents the vertical machining allowance in millimeters, set as a fixed value based on actual measurements of 50 threading cycles; the formula for calculating the horizontal opening size is: , in the formula This represents the opening size in the left and right directions, in millimeters. This represents the conductor width parameter, in millimeters. This represents the left-right machining allowance, in millimeters, and is set to a fixed value based on actual measurements from 50 threading processes. The adaptively superimposed heatmap of the vertical opening size distribution is shown below. Figure 2 As shown.

[0044] For example, the system obtains the position error of the pressure finger. It is 2 mm. Since the upper pressure finger is a vertical motion mechanism, the extraction coefficient for the vertical axis is... Set to a fixed value of 1, extract coefficients for the left and right axes. Set the value to a fixed 0. Substitute the value into the formula to calculate the positional error in the vertical direction. Millimeters, positional error in the left and right directions Millimeters. The system calls the preset gap compensation algorithm model and sets the compensation coefficients in the vertical direction. The inherent back clearance in the vertical direction is 1.1. The value is 0.5 mm. Substitute the value into the formula to calculate the clearance compensation value in the vertical direction. Millimeters. Set the compensation coefficient in the left and right directions. The inherent back clearance in the left and right directions is 1.2. The value is 0.4 mm. Substitute the value into the formula to calculate the clearance compensation value in the left and right directions. Millimeters. The system extracts the acquired conductor thickness. The conductor width parameter is 2 mm. The allowance is 5 mm. Set the vertical machining allowance. The allowance is 1 mm in the left and right directions. The value is 1.5 mm. Substitute the value into the formula to calculate the opening size in the vertical direction. Millimeters. Calculate the opening dimensions in the left and right directions. Millimeters. The calculated vertical and horizontal opening dimensions together constitute the opening dimensions that meet the requirements of current conductor specifications for threading and transposition. This process directly verifies the effectiveness of the gap compensation algorithm model.

[0045] Optionally, the step of calling a preset gap compensation algorithm model to convert the vertical position error and the horizontal position error into vertical gap compensation values ​​and horizontal gap compensation values ​​for eliminating mechanical transmission backlash includes: Based on the motion direction attribute of the position error, determine the direction of backlash in the mechanical transmission chain of each actuator; Based on the reverse clearance direction, the absolute value of the deviation is multiplied according to the preset compensation ratio coefficient, and then added to the corresponding axial and mechanism reference compensation amount obtained from the preset clearance compensation database to obtain the preliminary compensation value for each axial direction. The initial compensation value is subjected to upper and lower limit constraints, and the constrained values ​​are output as the gap compensation values ​​in the upper and lower directions and the gap compensation values ​​in the left and right directions, respectively.

[0046] Specifically, the control system reads the motion direction attribute inherent in the position error. This attribute refers to the spatial vector direction of the actual movement of the mechanical component, which is used to determine the direction of the backlash caused by the forward and reverse switching of the mechanical transmission chain of each actuator. The mechanical transmission chain is the physical mechanism that connects gears and lead screws to transmit power.

[0047] Based on the determined reverse clearance direction, algebraic operations are performed, and the core formula for the operation is: , in the formula The values ​​represent the initial compensation values ​​for each axis, and the unit is millimeters. This represents the absolute value of the deviation, i.e., the non-negative value of the difference between the actual coordinates and the ideal coordinates, in millimeters. It is obtained by the system by subtracting the actual position from the preset target position. This represents the preset compensation ratio coefficient, which is a dimensionless pure number set based on transmission testing. This represents the baseline compensation amount for the corresponding axial direction and mechanism, in millimeters. It is the inherent backlash value of the equipment obtained from a preset clearance compensation database.

[0048] After calculating the initial compensation value, the control program performs upper and lower limit constraints on it, that is, it presets a maximum allowable compensation boundary and a minimum allowable compensation boundary. When the initial compensation value exceeds the boundary, it is forcibly limited to the safe boundary value. Finally, the constrained values ​​are output as the gap compensation values ​​in the upper and lower directions and the gap compensation values ​​in the left and right directions, respectively, to the motor drive hardware to complete the calculation and conversion.

[0049] For example, the principle of the overall method lies in constructing an adaptive error correction mechanism combining hardware and software by separating dynamic error and static backlash and performing superimposed amplitude limiting calculations. In the test verification example of vertical compensation for the upper pressure finger mechanism, the system reads that the current motion direction attribute of the upper pressure finger is positive, thus determining that the backlash direction of the mechanical transmission chain is also positive. The system obtains the absolute value of the deviation in actual operation through a pre-comparison step. The value is 2 mm. Simultaneously, the control system retrieves the preset compensation ratio coefficient in the vertical direction from a table. The value is 1.1, and the reference compensation amount for the vertical axis of the upper pressure finger is accurately retrieved from the clearance compensation database. It is 0.5 mm. Substitute the above values ​​into the formula. Preliminary compensation value obtained The initial compensation value was measured in millimeters. The system then introduced upper and lower limit constraints on this preliminary compensation value, setting the maximum allowable compensation boundary of the mechanism to 3.0 millimeters and the minimum allowable compensation boundary to 0 millimeters. Since the calculated 2.7 millimeters fell within the constraint range of 0 to 3.0 millimeters, the system did not trigger the truncation limit and directly output 2.7 millimeters as the final vertical clearance compensation value.

[0050] S5. Control each servo actuator to complete the positioning according to the target position after superimposing the gap compensation value, and adjust the opening and closing distance of the pressure finger and the pressure plate according to the opening size; Optionally, controlling each servo actuator to complete positioning according to the target position after superimposing the gap compensation value, and adjusting the opening and closing distance of the pressure finger and pressure plate according to the opening size includes: The preset target positions of each servo actuator are superimposed with the corresponding backlash compensation values ​​to generate corrected absolute positioning coordinates for eliminating mechanical backlash. A motion command containing the corrected absolute positioning coordinates is sent to the driver of each servo actuator to drive each servo actuator to move and accurately position itself to the corrected target position. The generated opening size is converted into stroke control signals for the pressure fingers and pressure plates, and then sent to the servo driver that controls the pressure fingers and pressure plates. In response to the stroke control signal, the relative distance between the upper and lower pressure fingers and between the upper and lower pressure plates is adjusted.

[0051] Specifically, the preset target position represents the ideal coordinates that the mechanical component is expected to reach, calculated based on the conductor specifications. The corresponding clearance compensation value represents the compensation distance used to correct mechanical backlash along a specific motion axis. Corrected absolute positioning coordinates are generated through mathematical addition to eliminate mechanical backlash. The corrected absolute positioning coordinates represent the final physical space coordinates after compensating for transmission errors. The formula for calculating the corrected absolute positioning coordinates is: , in the formula This represents the corrected absolute positioning coordinates, in millimeters. This represents the preset target position, in millimeters. This represents the corresponding gap compensation value, in millimeters.

[0052] Motion commands containing corrected absolute positioning coordinates are sent to the drivers of each servo actuator. The driver represents an electronic device that receives control signals and converts them into motor drive current. The motion command represents a digital control signal containing target coordinates and speed parameters. The underlying hardware relies on these signals to drive each servo actuator to move and accurately position itself to the corrected target position. The corrected target position represents the backlash-free coordinates that the mechanical component actually reaches in physical space.

[0053] The control program converts the generated opening dimension into stroke control signals for the pressure fingers and pressure plates. The opening dimension represents the opening distance that the pressure fingers or pressure plates need to maintain during operation. The stroke control signal represents a sequence of digital pulses that the driver can recognize to control the motor's rotation angle. The formula for calculating the stroke control signal is: , in the formula This represents a stroke control signal and is dimensionless. This represents the open size, in millimeters. This represents the pulse equivalent conversion factor, measured in pulses per millimeter, and is set to a fixed value based on the encoder resolution of the device's servo motor.

[0054] The stroke control signal is sent to the servo driver that controls the pressure finger and the pressure plate. The servo driver is a motor drive device specifically designed for precise control of the position of the pressure finger and the pressure plate. The mechanical actuator responds to the stroke control signal and adjusts the relative distance between the upper and lower pressure fingers and between the upper and lower pressure plates. The upper and lower pressure fingers are actuators that press the wires from the top and bottom. The upper and lower pressure plates are plate-shaped components that flatten the wire arrangement from the top and bottom. The relative distance represents the spatial interval between the two corresponding components in the working state.

[0055] For example, the control system extracts the preset target position of the pressing finger. The corresponding gap compensation value is 16 mm. The value is 2.7 mm. Substituting the value into the formula, the corrected absolute positioning coordinates are calculated. Millimeters. The system sends motion commands containing corrected absolute positioning coordinates to the drivers of each servo actuator, driving each servo actuator to move and precisely position itself to the corrected target location. The system extracts the opening dimension of the upper pressure finger. The pulse equivalent conversion factor is set to 5.7 mm. The pulse count is 10,000 per millimeter. Substitute the value into the formula to calculate the stroke control signal. The system sends stroke control signals to the servo drives that control the pressure fingers and pressure plates. The mechanical actuators respond to the stroke control signals, precisely adjusting the relative distances between the upper and lower pressure fingers, as well as between the upper and lower pressure plates. This calculation process directly verifies the effectiveness of the corrected absolute positioning coordinate settings, ensuring that the mechanical components reach their accurate working positions.

[0056] S6. After detecting that the number of conductor columns, the spacing between them, and the staggered state meet the preset transposition process conditions, resume normal production mode.

[0057] Optionally, the step of restoring normal production mode after detecting that the number of conductor columns, the spacing between them, and the staggered state meet the preset transposition process conditions includes: Obtain the actual state feedback signal of the wire arrangement, and analyze the number of wire columns, the arrangement spacing, and the staggered state; The number of conductor columns, the spacing between them, and the staggered state are compared with the transposition process conditions to determine whether the state meets the standards. If the target is met, the corrected target position after superimposing the gap compensation value of each servo actuator and the opening and closing distance of the pressure finger and pressure plate will be saved as production parameters. Re-establish the synchronous linkage between the pressure finger and the main shaft cam linkage mechanism; Exit debug mode, switch to normal production mode, and run the program using the specified production parameters.

[0058] Specifically, the actual state feedback signal represents the digital image electrical signal collected by the vision sensor that reflects the current physical arrangement of the conductors; the number of conductor columns represents the number of longitudinal rows of conductors arranged side by side in the transposition mechanism; the arrangement spacing represents the physical distance between adjacent conductors; and the staggered state represents the relative displacement of the upper and lower conductors in the horizontal direction.

[0059] The transposition process conditions refer to a pre-set set of standard parameters that meet the requirements for producing qualified transposed cables. The judgment process is achieved by calculating the comprehensive process deviation rate. The formula for calculating the comprehensive process deviation rate is: , in the formula Represents the overall process deviation rate; dimensionless. Represents the number of conductors, dimensionless; The standard column number is dimensionless and is set based on the transposition process conditions. The column weight is dimensionless and set to a fixed value based on 100 production tests. Represents the spacing between elements, in millimeters; The standard spacing is represented in millimeters and is set based on transposition process conditions. The representative spacing weight is dimensionless and is set to a fixed value based on 100 production tests. This indicates a staggered arrangement, with the unit being millimeters. The standard offset is represented in millimeters and is set based on the transposition process conditions. This represents staggered weights, is dimensionless, and is set to a fixed value based on 100 production tests.

[0060] The deviation threshold represents the allowable proportion of process error, set based on the equipment's machining accuracy. After the target state is met, the corrected target position after superimposing the gap compensation value for each servo actuator, as well as the opening and closing distance between the pressure finger and the pressure plate, are saved as production parameters. The corrected target position represents the final physical space coordinates after eliminating mechanical transmission errors, and the opening and closing distance represents the relative distance maintained by the pressure finger and the pressure plate in the working state. The production parameters represent a fixed dataset used to control the equipment's operation in normal production mode. The control program drives the electromagnetic clutch to close, re-establishing the synchronous linkage between the pressure finger and the spindle's cam linkage mechanism. Synchronous linkage indicates the mechanical correlation characteristic where the pressure finger moves in a fixed proportion as the spindle rotates. After completing the above actions, the equipment exits the debugging state, the control system switches to normal production mode, and the production parameters are called for operation. Normal production mode represents the equipment's continuous and automatic shifting processing state according to the set parameters.

[0061] For example, the control system acquires the actual state feedback signal of the wire arrangement and analyzes it to determine the number of wire rows. The spacing is 2. It is 5.1 mm, in a staggered state. The value is 2.5 mm. The system extracts the standard column number from the transposition process conditions. The standard spacing is 2. The standard offset is 5.0 mm. It is 2.5 mm. Set the column weight. The spacing weight is 10. Set to 1, stagger weights The value is 1. Substitute the value into the formula to calculate the overall process deviation rate. The deviation threshold was set to 0.05. Since the calculated comprehensive process deviation rate of 0.02 was less than the deviation threshold of 0.05, the system determined that the status met the requirements. The system then saved the corrected target positions after superimposing the gap compensation values ​​for each servo actuator, as well as the opening and closing distances of the pressure fingers and pressure plates, as production parameters. The equipment re-established the synchronous linkage between the pressure fingers and the main shaft's cam linkage mechanism, exited the debugging state, switched to normal production mode, and started running using the production parameters. This calculation process directly verified the effectiveness of the status compliance judgment mechanism, ensuring that the equipment was put into production while meeting process requirements.

[0062] Optionally, the method further includes: If the standard is not met, the process deviation value between the actual state of the current wire arrangement and the transposition process conditions is extracted. Determine whether the process deviation value exceeds the preset mechanical tolerance safety threshold; If the mechanical tolerance safety threshold is not exceeded, the process deviation value is converted into a secondary compensation increment, updated and overwritten into the gap compensation value of the corresponding servo actuator, and the execution control of each servo actuator is returned to the target position after superimposed compensation value. If the mechanical tolerance safety threshold is exceeded, it is determined that there is mechanical interference or excessive wear, triggering an abnormal diagnosis alarm signal and controlling each servo actuator of the switching head to enter a safety lock state.

[0063] Specifically, when the wire arrangement is determined to be substandard, the control system first extracts the process deviation value between the actual state of the current wire arrangement and the transposition process conditions. The actual state refers to the physical arrangement dimensions captured by the sensors in real time, and the transposition process conditions refer to the preset standard qualified dimensions. The process deviation value is obtained by calculating the absolute difference between the two. The core formula for this calculation is: , in the formula This represents the process deviation value, in millimeters; Represents the actual spacing measured in millimeters; This represents the standard spacing specified in the transposition process conditions, in millimeters.

[0064] The system then determines whether the process deviation exceeds a preset mechanical tolerance safety threshold. This threshold represents the maximum single-correction limit physical distance allowed by the equipment's inherent mechanical rigidity, also measured in millimeters. If the process deviation does not exceed the mechanical tolerance safety threshold, the system converts the deviation into a secondary compensation increment using a conversion formula. , in the formula This represents the incremental compensation for the second time, expressed in millimeters. The coefficient representing the second-order compensation conversion is a dimensionless pure number set based on engineering debugging experience. This product operation makes the value have proportional convergence characteristics and completely retains the millimeter dimension.

[0065] After the conversion, the system linearly adds the secondary compensation increment to the original gap compensation value with the same dimensions, updates and overwrites the gap compensation value of the corresponding servo actuator, and then drives the control program back to control each servo actuator to perform secondary positioning and correction according to the target position after superimposing the latest compensation value. If the system determines that the process deviation value exceeds the preset mechanical tolerance safety threshold, it determines that the equipment currently has abnormal mechanical interference or severe excessive wear. The underlying logic immediately triggers abnormal diagnostic alarm signals such as audible and visual modules, and forcibly controls each servo actuator of the switching head to enter the cut-off enabled safety lock state to stop all actions. The logic diagram for process deviation value and mechanical tolerance safety judgment is as follows: Figure 3 As shown.

[0066] For example, in a test verification case where the conductor spacing did not meet the standard, the system calculated a comprehensive process deviation rate of 0.06, which exceeded the preset compliance threshold of 0.05, thus determining that the process did not meet the standard. The actual spacing was then further analyzed. The standard spacing is 5.2 mm. The horizontal process deviation value is 5.0 mm, obtained by subtraction difference calculation. =0.2 mm. The system's internal preset mechanical tolerance safety threshold is 0.5 mm. Since 0.2 mm does not exceed the threshold, it is judged as a normal mechanical transmission error. Subsequently, the system retrieves the preset horizontal direction secondary compensation conversion coefficient. =0.5, and the second-order compensation increment in the left and right directions is obtained through product operation. =0.2 × 0.5 = 0.1 mm. The system then adds this increment to the old left-right gap compensation value originally recorded in memory as 0.4 mm, obtaining a pre-compensation value of 0.5 mm. After verifying the upper and lower limits in millimeters, a new left and right gap compensation value of 0.5 millimeters is generated and overwritten with the original data. The left and right servo actuators are then instructed to reposition and adjust according to the corrected position to eliminate the gap deviation. Conversely, if the system measures the actual arrangement gap... Reaching 6.0 millimeters, calculated as follows If the deviation is less than 1.0 mm, exceeding the 0.5 mm threshold, it is considered severe mechanical interference, triggering an alarm and locking the equipment. Similarly, if a misalignment deviation is detected, the misalignment secondary compensation conversion coefficient is invoked. =0.1, range of values To meet high-precision positioning requirements, the secondary compensation increment is superimposed on the spindle clearance compensation value to correct the spindle rotation positioning coordinates. If a column deviation is detected, it is determined to be due to incorrect stop finger specifications or sensor failure. Secondary compensation is not performed, and an abnormal diagnosis alarm signal is directly triggered. The effectiveness of the fault tolerance mechanism is verified throughout the entire process.

[0067] Based on the same inventive concept, such as Figure 4 As shown, the present invention also provides an automatic switching head debugging system based on adaptive gap compensation, the system comprising: The initial state detection and parameter acquisition module is used to detect the spindle zero position of the transposition head and the initial state of each servo actuator, acquire the set conductor thickness, conductor width and conductor number parameters, and release the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging and startup. The debugging wizard guide and the transposition head control module is used to control the transposition head to move sequentially to the push finger replacement position, the single row wire threading position, the double row wire threading position, and the split and drag wire position according to the guidance of the debugging wizard, wherein the corresponding specification of the stop finger is matched according to the conductor width parameter. The automatic measurement and position error calculation module is used to generate the preset target position of each servo actuator based on the conductor thickness, conductor width and conductor number parameters during the automatic measurement stage, obtain the current actual position of the spindle, upper pressure finger, lower pressure finger, upper pressure plate, lower pressure plate, front left and right mechanism, rear left and right mechanism and rear up and down mechanism, and calculate the position error of each servo actuator. The gap compensation value and opening size generation module is used to automatically generate gap compensation values ​​and opening sizes in the vertical and horizontal directions for correction based on the position error. The positioning and spacing adjustment module is used to control each servo actuator to complete the positioning according to the target position after superimposing the gap compensation value, and to adjust the opening and closing spacing of the pressure finger and the pressure plate according to the opening size; The process condition detection and production mode recovery module is used to restore the normal production mode after detecting that the number of conductor columns, the spacing between them, and the staggered state meet the preset transposition process conditions.

[0068] It should be noted that the electrical connections between the various units described above do not necessarily represent direct or indirect connections. Any indirect connection method can be applied to the embodiments of the present invention as long as it achieves the purpose of the present invention. The above descriptions are merely exemplary embodiments of the present invention and should not be construed as limiting the scope of the present invention.

[0069] All equivalent changes and modifications made in accordance with the teachings of this invention are still within the scope of this invention. Those skilled in the art will readily conceive of other embodiments of this invention upon considering the specification and the disclosure of practical truth. This application is intended to cover any variations, uses, or adaptations of this invention that follow the general principles of this invention and include common knowledge or conventional techniques in the art not described herein.

Claims

1. An automatic switching head debugging method based on adaptive gap compensation, characterized in that... The method includes: The system detects the spindle zero position of the transposition head and the initial state of each servo actuator, obtains the set conductor thickness, conductor width and conductor number parameters, and releases the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging and starting. Guided by the debugging wizard, the switching head is controlled to move sequentially to the finger replacement position, the single-row wire threading position, the double-row wire threading position, and the split and drag wire position, wherein the corresponding specification of the blocking finger is matched according to the conductor width parameter. During the automatic measurement phase, the preset target positions of each servo actuator are generated based on the conductor thickness, conductor width, and conductor number parameters. The current actual positions of the spindle, upper pressure finger, lower pressure finger, upper pressure plate, lower pressure plate, front left and right mechanism, rear left and right mechanism, and rear up and down mechanism are obtained, and the position error of each servo actuator is calculated. Based on the positional error, automatic generation of clearance compensation values ​​and opening dimensions in the vertical and horizontal directions for correction is performed. Each servo actuator is controlled to complete the positioning according to the target position after superimposing the gap compensation value, and the opening and closing distance of the pressure finger and the pressure plate is adjusted according to the opening size; Once the number of conductor columns, spacing, and staggered state meet the preset transposition process conditions, normal production mode is restored.

2. The automatic head adjustment method based on adaptive gap compensation according to claim 1, characterized in that, The function of detecting the spindle zero position of the transposition head and the initial state of each servo actuator, obtaining the set conductor thickness, conductor width, and conductor number parameters, and releasing the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging and startup includes: Acquire the spindle position data and verify the spindle zero position, and check whether each servo actuator is in a standby state that allows debugging; Record the set conductor thickness, conductor width, and number of conductors, and use them as reference parameters for generating the target position of the servo actuator. Also, cut off the synchronous linkage between the pressure finger and the spindle cam linkage mechanism.

3. The automatic switching head debugging method based on adaptive gap compensation according to claim 1, characterized in that, Guided by the debugging wizard, the switching head is controlled to move sequentially to the finger replacement position, the single-row threading position, the double-row threading position, and the split-row and drag-wire position. The finger stoppers, matched to the appropriate specifications based on the conductor width parameters, include: Extract the acquired conductor width parameters and select the stop finger corresponding to the size of the conductor width parameters; Start the debugging wizard and issue the corresponding movement commands in sequence according to the preset debugging steps. The switching head is controlled to respond to the movement command and is positioned step by step to the push finger replacement position, single-row threading position, double-row threading position, and split-row and dragging position.

4. The automatic switching head debugging method based on adaptive gap compensation according to claim 1, characterized in that, The calculation of the position error of each servo actuator includes: Extract the current actual position and preset target position of each servo actuator; The current actual position of each servo actuator is compared with its corresponding preset target position, and the difference is calculated to obtain the absolute value of the deviation between the two. The direction of movement of the current actual position deviating from the preset target position is determined, and a position error with directional attributes is generated by combining the absolute value of the deviation.

5. The automatic head adjustment method based on adaptive gap compensation according to claim 1, characterized in that, The automatic generation of clearance compensation values ​​and opening dimensions in the vertical and horizontal directions based on the position error includes: The position error is analyzed according to the motion axis corresponding to each servo actuator, and is divided into position error in the vertical direction and position error in the horizontal direction. The preset gap compensation algorithm model is invoked to convert the position errors in the vertical and horizontal directions into gap compensation values ​​in the vertical and horizontal directions, respectively, for eliminating mechanical transmission backlash. Extract the acquired conductor thickness and conductor width parameters, and then superimpose the conductor thickness and conductor width parameters with the gap compensation values ​​in the vertical direction and the horizontal direction, respectively, to generate an opening size that meets the requirements of the current conductor specification for threading and transposition.

6. The automatic switching head debugging method based on adaptive gap compensation according to claim 1, characterized in that, The process of controlling each servo actuator to complete positioning according to the target position after superimposing the gap compensation value, and adjusting the opening and closing distance of the pressure finger and pressure plate according to the opening size includes: The preset target positions of each servo actuator are superimposed with the corresponding backlash compensation values ​​to generate corrected absolute positioning coordinates for eliminating mechanical backlash. A motion command containing the corrected absolute positioning coordinates is sent to the driver of each servo actuator to drive each servo actuator to move and accurately position itself to the corrected target position. The generated opening size is converted into stroke control signals for the pressure fingers and pressure plates, and then sent to the servo driver that controls the pressure fingers and pressure plates. In response to the stroke control signal, the relative distance between the upper and lower pressure fingers and between the upper and lower pressure plates is adjusted.

7. The automatic head adjustment method based on adaptive gap compensation according to claim 1, characterized in that, The process of restoring normal production mode after detecting that the number of conductor columns, the spacing between them, and the staggered state meet the preset transposition process conditions includes: Obtain the actual state feedback signal of the wire arrangement, and analyze the number of wire columns, the arrangement spacing, and the staggered state; The number of conductor columns, the spacing between them, and the staggered state are compared with the transposition process conditions to determine whether the state meets the standards. If the target is met, the corrected target position after superimposing the gap compensation value of each servo actuator and the opening and closing distance of the pressure finger and pressure plate will be saved as production parameters. Re-establish the synchronous linkage between the pressure finger and the main shaft cam linkage mechanism; Exit debug mode, switch to normal production mode, and run the program using the specified production parameters.

8. The automatic switching head debugging method based on adaptive gap compensation according to claim 5, characterized in that, The step of calling a preset gap compensation algorithm model to convert the vertical and horizontal position errors into vertical and horizontal gap compensation values ​​for eliminating mechanical transmission backlash includes: Based on the motion direction attribute of the position error, determine the direction of backlash in the mechanical transmission chain of each actuator; Based on the reverse clearance direction, the absolute value of the deviation is multiplied according to the preset compensation ratio coefficient, and then added to the corresponding axial and mechanism reference compensation amount obtained from the preset clearance compensation database to obtain the preliminary compensation value for each axial direction. The initial compensation value is subjected to upper and lower limit constraints, and the constrained values ​​are output as the gap compensation values ​​in the upper and lower directions and the gap compensation values ​​in the left and right directions, respectively.

9. The automatic switching head debugging method based on adaptive gap compensation according to claim 7, characterized in that, The method further includes: If the standard is not met, the process deviation value between the actual state of the current wire arrangement and the transposition process conditions is extracted. Determine whether the process deviation value exceeds the preset mechanical tolerance safety threshold; If the mechanical tolerance safety threshold is not exceeded, the process deviation value is converted into a secondary compensation increment, updated and overwritten into the gap compensation value of the corresponding servo actuator, and the execution control of each servo actuator is returned to the target position after superimposed compensation value. If the mechanical tolerance safety threshold is exceeded, it is determined that there is mechanical interference or excessive wear, triggering an abnormal diagnosis alarm signal and controlling each servo actuator of the switching head to enter a safety lock state.

10. An automatic head-switching debugging system based on adaptive gap compensation, applied to the automatic head-switching debugging method based on adaptive gap compensation as described in any one of claims 1-9, characterized in that, The system includes: The initial state detection and parameter acquisition module is used to detect the spindle zero position of the transposition head and the initial state of each servo actuator, acquire the set conductor thickness, conductor width and conductor number parameters, and release the synchronous linkage function of the cam linkage mechanism between the pressure finger and the spindle before debugging and startup. The debugging wizard guide and the transposition head control module is used to control the transposition head to move sequentially to the push finger replacement position, the single row wire threading position, the double row wire threading position, and the split and drag wire position according to the guidance of the debugging wizard, wherein the corresponding specification of the stop finger is matched according to the conductor width parameter. The automatic measurement and position error calculation module is used to generate the preset target position of each servo actuator based on the conductor thickness, conductor width and conductor number parameters during the automatic measurement stage, obtain the current actual position of the spindle, upper pressure finger, lower pressure finger, upper pressure plate, lower pressure plate, front left and right mechanism, rear left and right mechanism and rear up and down mechanism, and calculate the position error of each servo actuator. The gap compensation value and opening size generation module is used to automatically generate gap compensation values ​​and opening sizes in the vertical and horizontal directions for correction based on the position error. The positioning and spacing adjustment module is used to control each servo actuator to complete the positioning according to the target position after superimposing the gap compensation value, and to adjust the opening and closing spacing of the pressure finger and the pressure plate according to the opening size; The process condition detection and production mode recovery module is used to restore the normal production mode after detecting that the number of conductor columns, the spacing between them, and the staggered state meet the preset transposition process conditions.

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