Metal wire performance detection integrated intelligent control system and method

Abstract

The application relates to the technical field of programmable logic control, and discloses a metal wire performance detection integrated intelligent control system and method, which comprises a main control logic module, a motion and tension driving module, a displacement pulse collection module, a multi-station comprehensive detection sensing module and a terminal action control module; the main control logic module is integrated with a hardware interrupt capture interface, a high-speed counting channel, an output comparison register, a time-space coordinate synchronous mapping module, a multi-stage task scheduling engine and a torque feedforward decoupling module; when it is detected that the state is out of bounds, the time stamp and the displacement coordinate are latched, the dynamic arrival time is solved to slide the overload output comparison register, and the target action unit is triggered in the hard real-time interrupt; the torque feedforward decoupling module extracts the linear velocity derivative to generate a compensation torque, the application eliminates the time-space phase truncation drift of discrete scanning and continuous displacement, improves the sorting action certainty and restrains tension oscillation.

Description

Technical Field

[0001] This invention relates to an integrated intelligent control system and method for testing the performance of metal wires, belonging to the field of programmable logic control technology. Background Technology

[0002] Online inspection equipment for metal wires typically uses a programmable logic controller (PLC) to coordinate wire feeding traction, multi-station sensor data acquisition, and downstream sorting. As wire running speed increases and the number of inspection parameters grows, the traditional control method, which uses a fixed time cycle for cyclic scanning, becomes increasingly limited in terms of control accuracy and response speed. During continuous wire operation, the wire position is constantly changing, and the sampling times of laser diameter measurement, cross-sectional profile scanning, and dynamic tension sensing signals are not synchronized with the controller's scanning and calculation times. When the wire speed fluctuates, the spatial coordinates calculated according to the fixed scanning cycle will gradually deviate, making it difficult for the end-effector to align with the defect point at the correct time. At the same time, when multiple inspection stations simultaneously report non-periodic out-of-tolerance events, the concentrated data entering the controller in a short period of time can easily cause input buffer blockage and competition for processing resources, resulting in uncontrolled jitter in the main control scanning cycle. This, in turn, affects the real-time determinism of multi-axis servo motion synchronous control. Furthermore, fluctuations in traction speed can also easily cause changes in the axial tension of the wire, causing lateral mechanical jitter when the wire passes through the measuring light curtain and resulting in false deformation readings.

[0003] Existing conventional software control logic also has limitations in terms of timing control and spatial mapping. For example, Chinese invention patent CN101509881B discloses an online leakage current detection method for enameled wire. It connects the PLC's digital or analog input terminals to a detection wheel, relies on the integrated control system to acquire detection data, and cycles through the detection time in segments. However, this type of solution is deeply bound to the fixed cyclic scanning cycle of the PLC host at its underlying mechanism. It performs timing calculations based on the preset condition of uniform wire transmission. In actual operation, the wire generates continuous dynamic speed-changing displacement due to sudden changes in wire tension or transmission disturbances. At this time, a phase deviation occurs between the discrete software polling timing and the actual physical space coordinates. When the linear speed fluctuates, the spatial position calculated based on the fixed clock beat will generate cumulative truncation error. Increasing the controller's main frequency or shortening the scanning cycle is difficult to eliminate the time misalignment between asynchronous sampling and program polling. On the other hand, if the response time window of the action mechanism is widened, the accuracy of the sorting action in hitting the defect location will be reduced.

[0004] Therefore, the technical problem to be solved by this invention is how to achieve reliable spatiotemporal coordinate synchronization mapping, hierarchical task preemption scheduling, and torque feedforward decoupling compensation within a programmable logic controller, reduce the impact of discrete scan timing jitter and mechanical vibration on the control process, and enable multi-parameter detection data to accurately coordinate with the end effector. Summary of the Invention

[0005] To address the problems in the background art, the technical solution of the present invention is as follows: An integrated intelligent control system for metal wire performance testing, comprising:

[0006] The main control logic module integrates a hardware interrupt capture interface, a high-speed counting channel, an output comparison register, a spatiotemporal coordinate synchronization mapping module, a multi-level task scheduling engine, a torque feedforward decoupling module, and a lock-free circular event queue.

[0007] Motion and tension drive module, used to adjust wire speed and tension;

[0008] The displacement pulse acquisition module outputs displacement pulses to the high-speed counting channel to generate absolute displacement coordinates.

[0009] The multi-station integrated detection and sensing module outputs a status out-of-bounds signal to the hardware interrupt capture interface;

[0010] The end effector control module is deployed downstream to output action control signals;

[0011] When a state out-of-bounds signal is received, the hardware interrupt capture interface latches the microsecond timestamp and absolute displacement coordinates; the spatiotemporal coordinate synchronization mapping module calculates the remaining distance based on the absolute displacement coordinates and the distance between the target action unit, calculates the linear velocity and acceleration based on the high-speed counting channel within the synchronization period, and solves the dynamic arrival time to slide the overload output comparison register; the multi-level task scheduling engine matches the output comparison register within the hard real-time interrupt to trigger the target action unit to act.

[0012] The torque feedforward decoupling module extracts the first derivative of the linear velocity to generate an additional torque compensation amount, which is then written into the torque register to suppress tension oscillations.

[0013] Preferably, the multi-level task scheduling engine constructs three mutually isolated task execution domains, including: the first layer is a hard real-time interrupt control layer with an execution period of 100μs and a clock jitter of less than 2μs, used to respond to hardware event matching of high-speed pulse capture, microsecond timestamp latching, emergency limit interlocking, and output comparison register; the second layer is a deterministic synchronous scanning layer with an execution period of 1ms, used to calculate multi-axis servo motion synchronization control algorithms, torque feedforward decoupling compensation, and periodic parsing of bus sensor messages; the third layer is an asynchronous data processing and status arbitration layer with an execution period of 5ms, used to complete multi-station quality data threshold comparison, out-of-tolerance event recording and packaging, and human-machine interaction communication; the main control logic module establishes a lockless circular event queue between the first and third layers for cross-layer transmission of action data packets containing action type codes, trigger target cycles, and unit physical addresses.

[0014] Preferably, when a hardware interrupt occurs at the first level or a deterministic clock tick occurs at the second level, the multi-level task scheduling engine immediately protects and suspends the task context of the third level, prioritizing the allocation of processor computing power to respond to high-priority control tasks; after exiting the interrupt service routine, the computational flow of the third level is restored to block the jitter interference of multi-station concurrent detection data on the scanning cycle of the motion control loop.

[0015] Preferably, the multi-station integrated detection sensing module includes a dynamic tension sensing unit; the torque feedforward decoupling module calculates the additional torque compensation based on the target tension setpoint, the feedback tension value sampled in real time by the dynamic tension sensing unit, and the first derivative of the real-time linear velocity; the additional torque compensation includes a feedforward component based on the product of the system rotational inertia feedforward compensation coefficient and the first derivative, and a closed-loop feedback component based on the proportional adjustment coefficient, the integral adjustment coefficient, and the tension deviation; the main control logic module writes the calculated additional torque compensation into the torque feedforward channel of the motion and tension drive module in each 1ms synchronous scan cycle to proactively eliminate the mechanical transmission inertial lag caused by traction speed variations.

[0016] Preferably, the multi-station integrated detection sensing module includes a dual-axis laser diameter measuring unit deployed at the first detection station; the dual-axis laser diameter measuring unit uses the nominal diameter of the wire as the central reference and sets the allowable range of symmetrical tolerance to ±0.10mm; when the real-time acquired outer diameter measurement value exceeds the allowable range of symmetrical tolerance, the main control logic module generates a dimensional deviation event and opens a tracking node for the corresponding physical segment of the wire in the unlocked ring event queue.

[0017] Preferably, the multi-station integrated detection sensing module includes a cross-sectional profile scanning unit deployed at the second detection station; the cross-sectional profile scanning unit acquires the maximum and minimum outer diameters of the wire in the orthogonal direction in real time; the main control logic module calculates the percentage ratio of the absolute value of the difference between the maximum and minimum outer diameters to the nominal diameter to characterize the relative deformation rate of the cross section; when the relative deformation rate of the cross section is greater than 1.0%, the main control logic module triggers a cross-sectional distortion out-of-tolerance event, and performs spatiotemporal coordinate overlap and merging of the cross-sectional distortion out-of-tolerance event with the dimensional out-of-tolerance events already recorded in the same wire section in the unlocked ring event queue.

[0018] Preferably, the end-effector control module includes a bidirectional sorting and guiding control unit, which includes a reversing control loop and a diversion path; the main control logic module maintains a normally open path when it determines that the multi-dimensional detection indicators of the corresponding wire physical section are all within the qualified set range; when any out-of-tolerance event is determined, a reversing level signal is output to the reversing control loop at the action trigger time calculated by the sliding heavy load, controlling the diversion channel to switch the unqualified wire section to the waste collection path.

[0019] Preferably, the end-effector control module further includes an inkjet marking control unit and a fixed-length cutting control unit; the spatiotemporal coordinate synchronization mapping module constructs independent trigger channels corresponding one-to-one with the inkjet marking control unit, the fixed-length cutting control unit, and the bidirectional sorting guide control unit according to the reference installation spacing of each unit along the transmission path; when a defect is detected, the main control logic module controls the inkjet marking control unit to output a color mark drive signal when the corresponding defect point reaches the marking position, and triggers the sorting action after the defect section enters the sorting interval.

[0020] Preferably, the multi-station integrated detection sensing module also includes a joint detection sensing unit; the main control logic module monitors the joint signal and records the segment position of the material in the tray. When the second joint signal input is detected, the fixed-length cutting control unit is scheduled to output a cutting control signal and link the bidirectional sorting and guiding control unit to guide the joint waste into the waste collection path to complete the automatic tray sorting.

[0021] An integrated intelligent control method for metal wire performance testing, applied to an integrated intelligent control system for metal wire performance testing, includes the following steps:

[0022] Step S1: The motion and tension drive module drives the wire transmission and adjusts the wire's running linear speed and tension; the displacement pulse acquisition module acquires the wire displacement pulses and transmits them to the high-speed counting channel to accumulate and generate real-time absolute displacement coordinates.

[0023] Step S2: The multi-station integrated detection sensor module collects multi-dimensional quality detection signals of the wire. When the quality status exceeds the limit, it outputs a status exceedance signal to the hardware interrupt capture interface. The hardware interrupt capture interface responds to the status exceedance signal and latches the microsecond timestamp of the detection time and the absolute displacement coordinate of the detection time.

[0024] Step S3: The spatiotemporal coordinate synchronization mapping module calculates the remaining physical distance based on the absolute displacement coordinates at the detection time and the reference geometric distance between the target action unit. During the synchronous scanning cycle, it calculates the real-time linear velocity and acceleration based on the pulse frequency change rate of the high-speed counting channel. It then calculates the dynamic arrival time corresponding to the remaining physical distance and outputs the count value of the comparison register under sliding overload.

[0025] Step S4: The multi-level task scheduling engine matches the output comparison register within the hard real-time interrupt and triggers the target action unit action of the end action control module.

[0026] In step S5, the torque feedforward decoupling module extracts the first derivative of the real-time linear velocity to generate an additional torque compensation amount, and then superimposes the additional torque compensation amount into the torque register of the motion and tension drive module to suppress tension oscillations caused by wire speed fluctuations.

[0027] Compared with the prior art, the beneficial effects of the present invention are:

[0028] 1. In the integrated intelligent control of metal wire performance testing, the high-speed counting channel and hardware interrupt capture interface are used to record the wire displacement and defect detection time. The trigger time of the output comparison register is adjusted in a timely manner according to the change of wire speed, so that the end action mechanism can follow the defect point more accurately. When the wire is accelerating or decelerating, the position deviation caused by fixed cycle polling can be reduced, so that the control command corresponds to the actual time when the defect arrives at the action mechanism, thereby improving the defect position tracking accuracy and the reliability of sorting action.

[0029] 2. By using a multi-level task scheduling engine to separate hard real-time control, synchronous scanning, and asynchronous data processing, and by using a lockless circular event queue to pass events between different levels, high-speed pulse capture and servo synchronous control can be prioritized when multiple detection stations report abnormal data at the same time. This reduces the occupation and contention of controller processing resources by sudden detection data, reduces scanning cycle jitter, and enables the controller to maintain a stable and deterministic control timing even when there is a lot of detection data and a high task load.

[0030] 3. By combining dynamic tension feedback with torque feedforward decoupling compensation, the influence of mechanical transmission inertia can be compensated in a timely manner when the traction speed changes. This can reduce wire tension fluctuations and lateral mechanical vibration when passing through the inspection station, thereby reducing false deformation readings caused by mechanical vibration, improving the signal-to-noise ratio of geometric dimensions and cross-sectional shape detection signals, and making the detection results more stable and consistent. Attached Figure Description

[0031] Figure 1 This is a flowchart of the online wire detection and end-effector triggering process of the present invention;

[0032] Figure 2 This is a state transition diagram for multi-station control and fault-safe switching in this invention.

[0033] The objectives, features, and advantages of this invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0034] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0035] An integrated intelligent control system for testing the performance of metal wires, comprising:

[0036] The main control logic module integrates a hardware interrupt capture interface, a high-speed counting channel, an output comparison register, a spatiotemporal coordinate synchronization mapping module, a multi-level task scheduling engine, a torque feedforward decoupling module, and a lock-free circular event queue.

[0037] Motion and tension drive module, used to adjust wire speed and tension;

[0038] The displacement pulse acquisition module outputs displacement pulses to the high-speed counting channel to generate absolute displacement coordinates.

[0039] The multi-station integrated detection and sensing module outputs a status out-of-bounds signal to the hardware interrupt capture interface;

[0040] The end effector control module is deployed downstream to output action control signals;

[0041] When a state out-of-bounds signal is received, the hardware interrupt capture interface latches the microsecond timestamp and absolute displacement coordinates; the spatiotemporal coordinate synchronization mapping module calculates the remaining distance based on the absolute displacement coordinates and the distance between the target action unit, calculates the linear velocity and acceleration based on the high-speed counting channel within the synchronization period, and solves the dynamic arrival time to slide the overload output comparison register; the multi-level task scheduling engine matches the output comparison register within the hard real-time interrupt to trigger the target action unit to act.

[0042] The torque feedforward decoupling module extracts the first derivative of the linear velocity to generate an additional torque compensation amount, which is then written into the torque register to suppress tension oscillations.

[0043] Preferably, the multi-level task scheduling engine constructs three mutually isolated task execution domains, including: the first layer is a hard real-time interrupt control layer with an execution period of 100μs and a clock jitter of less than 2μs, used to respond to hardware event matching of high-speed pulse capture, microsecond timestamp latching, emergency limit interlocking, and output comparison register; the second layer is a deterministic synchronous scanning layer with an execution period of 1ms, used to calculate multi-axis servo motion synchronization control algorithms, torque feedforward decoupling compensation, and periodic parsing of bus sensor messages; the third layer is an asynchronous data processing and status arbitration layer with an execution period of 5ms, used to complete multi-station quality data threshold comparison, out-of-tolerance event recording and packaging, and human-machine interaction communication; the main control logic module establishes a lockless circular event queue between the first and third layers for cross-layer transmission of action data packets containing action type codes, trigger target cycles, and unit physical addresses.

[0044] Preferably, when a hardware interrupt occurs at the first level or a deterministic clock tick occurs at the second level, the multi-level task scheduling engine immediately protects and suspends the task context of the third level, prioritizing the allocation of processor computing power to respond to high-priority control tasks; after exiting the interrupt service routine, the computational flow of the third level is restored to block the jitter interference of multi-station concurrent detection data on the scanning cycle of the motion control loop.

[0045] Preferably, the multi-station integrated detection sensing module includes a dynamic tension sensing unit; the torque feedforward decoupling module calculates the additional torque compensation based on the target tension setpoint, the feedback tension value sampled in real time by the dynamic tension sensing unit, and the first derivative of the real-time linear velocity; the additional torque compensation includes a feedforward component based on the product of the system rotational inertia feedforward compensation coefficient and the first derivative, and a closed-loop feedback component based on the proportional adjustment coefficient, the integral adjustment coefficient, and the tension deviation; the main control logic module writes the calculated additional torque compensation into the torque feedforward channel of the motion and tension drive module in each 1ms synchronous scan cycle to proactively eliminate the mechanical transmission inertial lag caused by traction speed variations.

[0046] Preferably, the multi-station integrated detection sensing module includes a dual-axis laser diameter measuring unit deployed at the first detection station; the dual-axis laser diameter measuring unit uses the nominal diameter of the wire as the central reference and sets the allowable range of symmetrical tolerance to ±0.10mm; when the real-time acquired outer diameter measurement value exceeds the allowable range of symmetrical tolerance, the main control logic module generates a dimensional deviation event and opens a tracking node for the corresponding physical segment of the wire in the unlocked ring event queue.

[0047] Preferably, the multi-station integrated detection sensing module includes a cross-sectional profile scanning unit deployed at the second detection station; the cross-sectional profile scanning unit acquires the maximum and minimum outer diameters of the wire in the orthogonal direction in real time; the main control logic module calculates the percentage ratio of the absolute value of the difference between the maximum and minimum outer diameters to the nominal diameter to characterize the relative deformation rate of the cross section; when the relative deformation rate of the cross section is greater than 1.0%, the main control logic module triggers a cross-sectional distortion out-of-tolerance event, and performs spatiotemporal coordinate overlap and merging of the cross-sectional distortion out-of-tolerance event with the dimensional out-of-tolerance events already recorded in the same wire section in the unlocked ring event queue.

[0048] Preferably, the end-effector control module includes a bidirectional sorting and guiding control unit, which includes a reversing control loop and a diversion path; the main control logic module maintains a normally open path when it determines that the multi-dimensional detection indicators of the corresponding wire physical section are all within the qualified set range; when any out-of-tolerance event is determined, a reversing level signal is output to the reversing control loop at the action trigger time calculated by the sliding heavy load, controlling the diversion channel to switch the unqualified wire section to the waste collection path.

[0049] Preferably, the end-effector control module further includes an inkjet marking control unit and a fixed-length cutting control unit; the spatiotemporal coordinate synchronization mapping module constructs independent trigger channels corresponding one-to-one with the inkjet marking control unit, the fixed-length cutting control unit, and the bidirectional sorting guide control unit according to the reference installation spacing of each unit along the transmission path; when a defect is detected, the main control logic module controls the inkjet marking control unit to output a color mark drive signal when the corresponding defect point reaches the marking position, and triggers the sorting action after the defect section enters the sorting interval.

[0050] Preferably, the multi-station integrated detection sensing module also includes a joint detection sensing unit; the main control logic module monitors the joint signal and records the segment position of the material in the tray. When the second joint signal input is detected, the fixed-length cutting control unit is scheduled to output a cutting control signal and link the bidirectional sorting and guiding control unit to guide the joint waste into the waste collection path to complete the automatic tray sorting.

[0051] An integrated intelligent control method for metal wire performance testing, applied to an integrated intelligent control system for metal wire performance testing, includes the following steps:

[0052] Step S1: The motion and tension drive module drives the wire transmission and adjusts the wire's running linear speed and tension; the displacement pulse acquisition module acquires the wire displacement pulses and transmits them to the high-speed counting channel to accumulate and generate real-time absolute displacement coordinates.

[0053] Step S2: The multi-station integrated detection sensor module collects multi-dimensional quality detection signals of the wire. When the quality status exceeds the limit, it outputs a status exceedance signal to the hardware interrupt capture interface. The hardware interrupt capture interface responds to the status exceedance signal and latches the microsecond timestamp of the detection time and the absolute displacement coordinate of the detection time.

[0054] Step S3: The spatiotemporal coordinate synchronization mapping module calculates the remaining physical distance based on the absolute displacement coordinates at the detection time and the reference geometric distance between the target action unit. During the synchronous scanning cycle, it calculates the real-time linear velocity and acceleration based on the pulse frequency change rate of the high-speed counting channel. It then calculates the dynamic arrival time corresponding to the remaining physical distance and outputs the count value of the comparison register under sliding overload.

[0055] Step S4: The multi-level task scheduling engine matches the output comparison register within the hard real-time interrupt and triggers the target action unit action of the end action control module.

[0056] In step S5, the torque feedforward decoupling module extracts the first derivative of the real-time linear velocity to generate an additional torque compensation amount, and then superimposes the additional torque compensation amount into the torque register of the motion and tension drive module to suppress tension oscillations caused by wire speed fluctuations.

[0057] Example 1: In this example, the main control logic module adopts a programmable logic controller and is built on an industrial fieldbus architecture. Its input terminal is connected and coupled to a high-precision displacement pulse acquisition module at the axle end of the driven traction speed measuring wheel. The driven speed measuring wheel has a circumference of 200mm and outputs 2000 orthogonal coded pulses per revolution, corresponding to the physical displacement equivalent coefficient. At a pulse rate of 0.10 mm / pulse, at the baseline linear velocity The reference synchronous scan cycle configured for the main control logic module under steady-state operation conditions of 10 m / s, or 10000 mm / s. The standard theoretical pulse increment accumulated by the encoder within a single cycle is 1ms. 100 pulses correspond to a single-cycle spatial displacement increment. The diameter is 10mm. A dual-axis laser diameter measuring unit, a cross-sectional profile scanning unit, and a dynamic tension sensing unit are rigidly arranged sequentially along the wire's travel path. The installation reference physical coordinates of the dual-axis laser diameter measuring unit are specified. The physical coordinates of the 500mm cross-sectional profile scanning unit are the mounting reference. The measurement range of the dynamic tension sensing unit is 0 to 500 N, with a length of 1200 mm; downstream of the biaxial laser diameter measuring unit, at the reference distance... A bidirectional sorting and guiding control unit is arranged at a position of 2000mm. The inherent hardware response delay constant of its pneumatic sorting and guiding mechanism... The calibration is set to 0.005s, or 5ms. When the high-speed wire is subjected to sudden changes in the tension of the wire winding and mechanical transmission disturbances, the line speed will produce slight pulsations. The wire will exhibit lateral mechanical jitter in the optical measurement light curtain. Asynchronous phase truncation lag will occur simultaneously between the fixed-period polling sampling and the continuous physical displacement, causing the physical point of the defect to shift in space during the multi-station flow process.

[0058] The wire is at the baseline speed Run to hardware microsecond clock to record timestamps At 0s, the dual-axis laser diameter measuring unit at the first detection station samples the instantaneous outer diameter measurement value. It is 4.12mm, exceeding the nominal diameter. The upper limit of the symmetrical tolerance range of 3.90mm to 4.10mm, set for 4.00mm, triggers the dimensional out-of-tolerance logic flag. For high-strength coiled spring steel wire with a nominal diameter of 4.00mm and a tensile strength of 850MPa, the symmetrical tolerance range is set to ±0.10mm, based on the mechanical meshing clearance tolerance requirements of the downstream high-precision CNC spring coiling machine's wire feeding rollers. When the outer diameter deviation exceeds ±0.10mm, it will cause wire feeding slippage or mold jamming. The relative deformation rate threshold of the cross-section is set to 1.0%, based on... This serves as the engineering critical criterion for determining the torsional fatigue limit of steel wire. When the ratio of the difference between the maximum and minimum outer diameters to the nominal diameter exceeds 1.0%, it indicates that there is die wear during wire drawing, causing the cross-section to become elliptical and out of round. During subsequent high-speed coil spring torsion forming, a significant stress concentration zone forms at the edge of the short axis, reducing the dynamic fatigue life of the finished spring by more than 30%. Therefore, 1.0% is used as the scrap threshold. The high-speed hardware interrupt capture interface of the main control logic module responds to the dimensional deviation signal and latches the absolute displacement coordinates currently accumulated by the hardware counter. It has a resolution of 5000mm and simultaneously latches microsecond timestamps. The multi-level task scheduling engine divides the control task into three mutually isolated task execution domains. The first layer is a hard real-time interrupt control layer with a base period of 100μs and a clock jitter of less than 2μs. The second layer is a deterministic synchronous scanning layer with a base period of 1ms. The third layer is an asynchronous data processing and status arbitration layer with a base period of 5ms. When the hardware interrupt of the first layer is triggered, the multi-level task scheduling engine protects and suspends the task context of the third layer. It prioritizes pushing the action data packet containing the detected coordinates, timestamps, and action codes into the lockless circular event queue within a microsecond-level time window. After exiting the interrupt service routine, it resumes the operation of the third layer. When the 1ms deterministic clock tick of the second layer arrives, it also protects and suspends the task context of the third layer first, prioritizes the execution of the synchronous control operation of the second layer, and resumes the original operation flow of the third layer after the second layer task is completed. The counting and matching of the end action control signal adopts a field-programmable gate array or a dedicated hardware output comparator inside the microprocessor. The main control logic module writes the calculated target pulse comparison value and action level status into the output comparison register in advance in the 100μs period hard real-time interrupt service routine.

[0059] When the real-time pulse value of the underlying high-speed counter decreases or accumulates to equal the value of the output comparison register under the hardware clock tick, the hardware comparison logic generates a matching event within a nanosecond-level physical response time. The multi-level task scheduling engine matches the output comparison register within a hard real-time interrupt and triggers the bidirectional sorting and guiding control unit action. The physical output pin generates a level transition accordingly. This hardware comparison process does not rely on the software polling of the central processing unit, keeping the clock jitter of the hardware action trigger within 2μs under a 100μs software task scheduling cycle. At the same time, the torque feedforward decoupling module extracts the first-order time derivative of the linear velocity from the high-precision displacement pulse sequence output by the displacement pulse acquisition module. Combined with the real-time tension value sampled by the dynamic tension sensing unit With the target tension set value The additional torque compensation is calculated using the following formula within a 1ms synchronous scan period. : ,in, for Additional torque compensation at any given time; The first time derivative of the real-time linear velocity; The feedforward compensation coefficient for the system's moment of inertia. Set the target tension value. for Real-time dynamic tension values ​​sampled at various times. This is the proportional adjustment coefficient; This is the integral adjustment coefficient; As a time variable in the integral operation, the additional torque compensation is directly written into the torque feedforward register of the motion and tension drive module every 1ms cycle. This compensates for the mechanical transmission inertial lag when the traction speed begins to change, suppressing axial oscillation and lateral jitter of the wire when it passes through the diameter and contour detection station. In the calculation of the additional torque compensation, the dimension of the system rotational inertia feedforward compensation coefficient used in the feedforward component is N·m / (m / s²), which is multiplied by the first time derivative of the linear velocity to obtain the torque in the dimension of N·m. The proportional adjustment coefficient and integral adjustment coefficient in the closed-loop feedback component are pre-integrated with the equivalent radius conversion coefficient of 0.03183m for the main traction driven speed measuring wheel. The actual engineering dimension of the proportional adjustment coefficient is N·m / N, and the actual engineering dimension of the integral adjustment coefficient is N·m / (N·s). This converts the tension deviation into electromagnetic compensation torque acting on the rotor shaft end of the servo motor, so that both the feedforward component and the closed-loop feedback component correspond to the dimension of N·m.

[0060] During uniform speed operation, the spatiotemporal coordinate synchronization mapping module calculates the reference trigger time of the bidirectional sorting and guidance control unit according to the following formula. : ,in, The timestamp of the moment the out-of-tolerance event was detected. To detect the absolute displacement coordinates of the wire at a given time, These are the real-time absolute displacement coordinates for the current calculation cycle. The current instantaneous linear velocity, The reference geometrical physical distance from the first inspection station to the bidirectional sorting and guiding control unit is 2000 mm. The inherent hardware action delay constant of the pneumatic sorting guide mechanism in the bidirectional sorting guide control unit is 0.005s, which occurs at the moment of detection. and Under steady state, the reference trigger time is calculated. The time is 0.195s, or 195ms, which corresponds to spanning 195 baseline synchronous scan cycles, representing the time the wire travels to the timestamp. 0.050s, current absolute displacement coordinate When the wire reaches 5500mm, tension disturbance at the pay-off end causes servo speed reduction adjustment, and the main control logic module acquires constant linear acceleration. The velocity is -2000 mm / s²; at this point, the remaining physical travel distance from the defect point to the bidirectional sorting guide control unit is... Instantaneous linear velocity Attenuation to 9900 mm / s, the spatiotemporal coordinate synchronization mapping module invokes the discrete kinematics prediction equation: After substituting the parameters, the dynamic arrival time increment is obtained. The updated action trigger time is 0.154s. That is, 199ms. The main control logic module then slides and reloads the target cycle count from the 195th cycle to the 199th cycle in the lockless ring event queue, and writes the matching count value to the output comparison register to compensate for the spatial displacement lag during deceleration. When high-frequency continuous speed disturbance occurs during the operation of the wire, the spatiotemporal coordinate synchronization mapping module recalculates the remaining dynamic arrival time increment cycle by cycle according to the latest sampled real-time absolute displacement coordinates, real-time linear velocity and real-time acceleration in each 1ms deterministic synchronization scan cycle. The 1500mm long-distance dynamic speed change process is discretized into tens to hundreds of 1ms time steps. In each time step, a first-order constant acceleration is used for local tangential approximation, and the matching count value of the output comparison register is refreshed cycle by cycle. High-frequency discrete fitting is used to compensate for the spatial prediction drift caused by high-order acceleration and nonlinear disturbance, so that the bidirectional sorting guidance control unit performs sorting action according to the updated defect location arrival time.

[0061] Online material progress to timestamp At 0.070s, the cross-sectional profile scanning unit of the second inspection station collects orthogonal bidirectional diameter measurements of the same wire section, including the major axis diameter. It is 4.03mm, minor axis diameter The thickness is 3.98mm. The main control logic module, in the third-level asynchronous data processing and state arbitration layer, uses the formula... The relative deformation rate of the cross section was calculated. The deviation rate is 1.25%, exceeding the preset maximum relative deformation rate threshold of 1.0%. The state arbitration logic generates a cross-sectional distortion out-of-tolerance event and merges this event with the dimensional out-of-tolerance event already recorded at the first inspection station in the unlocked circular event queue, generating a global scrap marker. During this spatiotemporal coordinate overlap and merging, the second inspection station is located at the installation coordinate of 1200mm. The main control logic module, based on the fixed geometric distance of 700mm between the first and second inspection stations and combined with the current real-time absolute displacement coordinates, reverse-calculates the initial detection timestamp and event index number of the defective wire section at the first inspection station. Subsequently, the microprocessor uses a hardware pointer to reverse-search the historical structural slot corresponding to this spatial section in the valid pending nodes of the unlocked circular event queue, and performs a bitwise OR operation on the comprehensive quality status word in that slot. The dimensional deviation flag and cross-sectional distortion flag are merged into a single global scrap rejection instruction to avoid multiple conflicting action data packets in the same wire section. When the time progresses to the hard real-time interrupt window of the 199th scan cycle, the multi-level task scheduling engine matches the output comparison register in the first-level hard real-time interrupt control layer to trigger the action of the bidirectional sorting guide control unit. Its reversing control loop outputs a level jump drive signal to the bidirectional electromagnetic reversing valve, which drives the diversion slide in the diversion path to act when the wire defect cross-section enters the sorting interval, guiding the unqualified wire section containing dimensional deviation and cross-sectional distortion into the scrap collection path. When the qualified wire section passes through, the normal passage is maintained. Under the conditions of multi-station sudden abnormal concurrency and speed dynamic fluctuation, the control clock jitter is kept within 2μs, and the end sorting space alignment accuracy is kept within 0.1mm.

[0062] Example 2: The current main control logic module uses a programmable logic controller with a deterministic industrial fieldbus interface, and is equipped with a field-programmable gate array expansion board to form a hardware interrupt capture interface and a high-speed counting channel for hardware capture and counting of high-frequency displacement pulses. An incremental encoder is mechanically coupled to the shaft end of the main traction driven speed measuring wheel. The driven speed measuring wheel has a circumference of 200.0 mm and outputs 2000 orthogonal electrical pulses per revolution. The physical displacement equivalent coefficient... Set to 0.10 mm / pulse; baseline velocity The speed is 10.0 m / s, which is equivalent to 10000.0 mm / s. The main control logic module is configured with a synchronous scanning cycle. 1.0 ms corresponds to a single-cycle reference displacement increment. The diameter is 10.0 mm. The detection channel is rigidly arranged along the wire transmission direction with a dual-axis laser diameter measuring unit, a cross-sectional profile scanning unit, and a dynamic tension sensing unit. The installation coordinates of the dual-axis laser diameter measuring unit are specified. The installation coordinates of the cross-sectional profile scanning unit are 500.0 mm. The measurement range of the dynamic tension sensing unit is 0 to 500 N, with a diameter of 1200.0 mm. This is downstream of the biaxial laser diameter measuring unit, at the reference physical distance. A bidirectional sorting and guiding control unit is set at the 2000.0mm position, and its pneumatic sorting and guiding mechanism has an inherent hardware action delay constant. The calibration is set to 0.005s, or 5.0ms. This embodiment uses the nominal diameter. Continuous online testing was conducted on high-strength coiled alloy spring steel wire with a diameter of 4.00 mm and a tensile strength benchmark of 850 MPa. A periodic tension fluctuation component with an amplitude of ±45.0 N and a frequency of 12.0 Hz was injected into the servo mechanism at the wire feeding end. At the same time, the traction wire speed was varied within the range of 8000.0 mm / s to 12000.0 mm / s, and acceleration and deceleration transient changes from -3000.0 mm / s² to +2000.0 mm / s² were applied to form a test condition with mechanical vibration, discrete scanning phase change, and concurrent input of multi-station test data.

[0063] The test employed five control configurations. The test group of this invention retained the hardware interrupt capture interface, multi-level task scheduling engine, spatiotemporal coordinate synchronization mapping module, and torque feedforward decoupling module. Partially missing comparison group 1 maintained the remaining hardware and multi-level task scheduling structure unchanged, but removed the torque feedforward decoupling module, employing only conventional proportional-integral tension feedback closed-loop regulation. Partially missing comparison group 2 removed the hardware interrupt latch and discrete kinematics prediction overload logic, polling and reading the diameter and contour data and calculating the trigger timing with a fixed 10.0ms cyclic scan cycle. Out-of-range comparison group 3 increased the scheduling cycle of the first-layer hard real-time interrupt control layer to 300μs and relaxed the maximum clock jitter to 12μs. Out-of-range comparison group 4 increased the system rotational inertia feedforward compensation coefficient. The overdamped parameters are set to exceed the system's stability region. The continuous trace length for each group is 2000.0m, and the data acquisition system synchronously records the running linear velocity. Disturbance acceleration Dynamic tension fluctuation peak-to-peak value, task scheduling clock jitter, defect location spatial deviation, and end-of-line sorting action hit rate.

[0064] For the test group of this invention that retains all control elements, the first step is to operate at linear speed. The disturbance acceleration is 10000.0 mm / s. Under steady-state condition 1 (0.0 mm / s²), continuous detection was performed. The peak-to-peak value of dynamic tension fluctuation was 8.6 N, the task scheduling clock jitter was 1.1 μs, the defect location spatial deviation was +0.12 mm, and the end-sorting hit rate was 99.8%. Under condition 2 (maintaining a running linear speed of 10000.0 mm / s and applying a deceleration disturbance of -2000.0 mm / s²), the torque feedforward decoupling module generated additional torque compensation as the speed changed, and the spatiotemporal coordinate synchronization mapping module updated the dynamic arrival time according to the real-time displacement, real-time linear speed, and acceleration, and slid the heavy-load output comparison register. The corresponding measured peak-to-peak value of dynamic tension fluctuation was 9.4 N, the task scheduling clock jitter was 1.3 μs, and the defect location spatial deviation was -0. With a minimum sorting accuracy of 99.5%, the dynamic tension fluctuation peak-to-peak value was 11.2 N when the running line speed was increased to 12000.0 mm / s and an acceleration disturbance of +2000.0 mm / s² was applied to form condition 3. The task scheduling clock jitter was 1.4 μs, the defect positioning space deviation was +0.28 mm, and the minimum sorting accuracy was 99.2%. In condition 4, the running line speed was reduced to 8000.0 mm / s and a deceleration disturbance of -3000.0 mm / s² was applied. The dynamic tension fluctuation peak-to-peak value was 12.8 N, the task scheduling clock jitter was 1.5 μs, the defect positioning space deviation was -0.35 mm, and the minimum sorting accuracy was 98.9%.

[0065] To compare the tension suppression effect of the torque feedforward decoupling module, the partially missing comparison sample group 1 was operated under operating conditions 1 and 2 corresponding to the test group of this invention. Under operating condition 1 (10000.0 mm / s, 0.0 mm / s²), after retaining only the proportional-integral tension feedback closed loop, the peak-to-peak value of dynamic tension fluctuation was 58.4 N, the task scheduling clock jitter was 1.2 μs, the defect positioning spatial deviation was +0.22 mm, and the end-sorting action hit rate was 98.6%. At 10000.0 mm / s... Under condition 2 with a speed of -2000.0 mm / s², the torque feedforward component based on the first derivative of speed is lacking in the initial stage of the speed change. The peak-to-peak value of dynamic tension fluctuation increases to 69.2 N, the task scheduling clock jitter is 1.4 μs, the defect positioning space deviation is -0.31 mm, and the end sorting action hit rate is 97.4%. The tension change during the deceleration disturbance directly affects the wire, causing the wire to generate high-frequency lateral vibration in the laser measurement light curtain, which is superimposed on the outer diameter measurement signal to form a false dimensional deviation reading.

[0066] To verify the effectiveness of hardware interrupt latching and dynamic arrival time reload for defect location tracking, the partial missing control group 2 was modified to use a fixed 10.0ms cyclic scan cycle for polling. Under condition 1 with a running linear velocity of 10000.0mm / s and a disturbance acceleration of 0.0mm / s², the peak-to-peak value of dynamic tension fluctuation was 10.2N, but the task scheduling clock jitter reached 42.6μs, the defect location spatial deviation was +4.85mm, and the end-of-line sorting hit rate was 86.2%. Continuing at 10000.0mm / s and -2000.0m... When operating under condition 2 at m / s², the fixed-cycle polling cannot recalculate the dynamic arrival time according to the speed change and slide the heavy-load output comparison register. The peak-to-peak value of dynamic tension fluctuation is 12.1N, the task scheduling clock jitter is 58.3μs, the defect location spatial deviation expands to -14.60mm, and the end sorting action hit rate drops to 63.5%. After the speed changes from steady state to deceleration, the time error generated by static displacement calculation continues to accumulate in the downstream action position, and the spatial alignment deviation between the physical defect location and the bidirectional sorting guide control unit increases accordingly.

[0067] In the over-range control sample group 3, the same operating linear speed of 10000.0 mm / s and disturbance acceleration of -2000.0 mm / s² as in condition 2 were used, but the scheduling period of the first layer hard real-time interrupt control layer was set to 300 μs and the maximum clock jitter condition was relaxed. The test results showed that the peak-to-peak value of dynamic tension fluctuation was 10.8 N, the task scheduling clock jitter was 14.8 μs, the defect location spatial deviation was -2.15 mm, and the end sorting action hit rate was 91.2%. Under this condition, after the first layer task scheduling timing was extended, the output comparison matching generated a corresponding discrete timing delay, and the downstream triggering deviation of the defect location increased accordingly.

[0068] The out-of-range control sample group 4 also used a running linear velocity of 10000.0 mm / s and a disturbance acceleration of -2000.0 mm / s², and the system's moment of inertia feedforward compensation coefficient was also used. When the overdamping parameter is set to exceed the system's stable domain, the torque feedforward compensation becomes overcompensated, and the peak-to-peak value of dynamic tension fluctuation reaches 84.6 N. The task scheduling clock jitter remains at 1.6 μs, the defect location spatial deviation is -0.42 mm, and the end-of-line sorting hit rate is 96.1%. These results indicate that when the task scheduling and position tracking links are running, the feedforward compensation parameter exceeding the stable operating range will still directly amplify the tension disturbance. Therefore, the compensation parameter of the torque feedforward decoupling module needs to be kept within the system's stable domain.

[0069] In the aforementioned continuous routing test, under different input conditions from steady state and deceleration to high-speed acceleration and significant deceleration, the peak-to-peak value of dynamic tension fluctuation remained below 13.0N, the task scheduling clock jitter remained within 1.5μs, the defect location spatial deviation fell within the ±0.35mm tolerance zone, and the end-of-line sorting action hit rate remained above 98.9%. After the hardware interrupt capture interface latched the timestamp and absolute displacement coordinates of the detection moment, the spatiotemporal coordinate synchronization mapping module updated the dynamic arrival time according to the acceleration and deceleration state and slid the heavy-load output comparison register, so that the continuous physical displacement corresponded to the subsequent action triggering moment. The multi-level task scheduling engine processed multi-station concurrent detection data through task context protection and low-priority task suspension. The torque feedforward decoupling module generated feedforward compensation based on the speed change rate and combined it with the tension feedback control motion and tension drive module. All of the above processes worked together to achieve defect location tracking, deterministic task scheduling, and tension disturbance suppression. The bidirectional sorting guide control unit responded by outputting a comparison matching signal to perform sorting.

[0070] Example 3: This example uses a nominal diameter Using 4.00mm high-strength coiled alloy spring steel wire with a tensile strength of 850MPa, the key gain parameters in the torque feedforward decoupling module were calibrated. During system initialization and debugging, the main control logic module applied a short-time step test signal with an angular acceleration of 50.0 rad / s² to the main traction motor via a servo driver. The linear velocity change rate response curve was measured by the displacement pulse acquisition module installed at the axle end of the driven speed measuring wheel. Combined with the equivalent moment of inertia calculation value of the mechanical transmission system, the system's moment of inertia feedforward compensation coefficient was determined. The stable operating range was calibrated to be between 0.015 and 0.035 N·m / (m / s²), and the selected... It is 0.025 N·m / (m / s²); when When the inertial lag of the mechanical transmission is below 0.015 N·m / (m / s²), it cannot be fully compensated for under acceleration and deceleration conditions. When the torque exceeds 0.035 N·m / (m / s²), the servo motor exhibits torque overshoot oscillation. Subsequently, the wire maintains a reference linear velocity. With a steady-state operation of 10.0 m / s (10000.0 mm / s), a transient step disturbance of ±30.0 N is applied to the wire tensioning mechanism. The tension recovery response curve is collected by the dynamic tension sensing unit, and the proportional adjustment coefficient is adjusted according to the attenuation rate and overshoot. Set it to 1.20, and adjust the integral adjustment factor. The threshold is set to 0.15 N·m / (N·s), and an anti-integral saturation limiting threshold and a tension dead zone threshold of 15.0 N·m are configured in the torque feedforward decoupling module. The value is ±2.0N; when the dynamic tension is in real time... With the target tension set value When the absolute value of the deviation is less than 2.0N, the integral accumulation is frozen to reduce the disturbance of the torque command by the electrical measurement noise of the sensor.

[0071] During multi-station high-frequency detection, when sudden defect data is input concurrently, the main control logic module sets up a lock-free circular event queue between the hard real-time interrupt control layer with a base period of 100μs and a clock jitter of less than 2μs, and the asynchronous data processing and status arbitration layer with a base period of 5ms. The queue adopts a shared memory structure with a depth of 256 data nodes, and the write head pointer is maintained separately through hardware atomic operations. and reading the tail pointer When the dual-axis laser diameter measurement unit or cross-sectional profile scanning unit outputs a status out-of-range signal in the form of an out-of-range level, the hard real-time interrupt control layer suspends the task context of the asynchronous data processing and status arbitration layer, and the hardware interrupt capture interface latches the current absolute displacement coordinates of the high-speed counting channel. and microsecond timestamp Then, include the defect type code, action unit physical address, and target trigger cycle number. Action data packet writing The currently pointed-to storage slot increments after the write operation is complete. ,when Adding 1 and taking the modulo of 256 results in the following value: When the lock-free circular event queue reaches full capacity, the multi-level task scheduling engine performs priority downgrading arbitration, discards the inkjet marker description field, retains the commutation control word of the bidirectional sorting guidance control unit and the control word of the fixed-length cut-off control unit, and simultaneously writes a global scrap lock level to the output comparison register. The 256 data slots of the lock-free circular event queue are pre-allocated as standardized structure units of fixed byte length during system initialization. The structure reserves an action type flag byte, a target cycle count integer field, and an inkjet parameter description string buffer. When the queue is full, the multi-level task scheduling engine uses a single-cycle hardware atomic write instruction to set the inkjet marker enable flag in the current slot to the disabled value 0, and sets the bidirectional sorting guidance control and fixed-length cut-off action enable flags to the active value 1. It also skips the formatting and packaging of the inkjet content string and the bus transmission process, reducing the consumption of communication bandwidth and processor by burst data while maintaining the continuity of the circular queue memory and the lock-free atomic increment of the pointer.

[0072] During wire reel replacement, emergency speed reduction due to wire breakage, or reel connector switching, the spatiotemporal coordinate synchronization mapping module acquires the real-time linear velocity within each 1.0ms synchronization scan cycle. and instantaneous acceleration In solving for the remaining arrival time increment Discriminant validity check is used. : ,in, The remaining physical distance from the defect point to the target action unit, when emergency braking generates a large deceleration and makes... When the value is less than zero, the wire will stop before reaching the downstream execution station. The spatiotemporal coordinate synchronization mapping module suspends the quadratic equation root-finding operation and freezes the output comparison and matching count value in the current register; waiting... After the speed rises back to the 1000.0 mm / s start-up threshold, the dynamic arrival time is calculated based on the real-time displacement recovery. A joint detection sensing unit is also set upstream of the multi-station integrated detection sensing module. When the first joint signal of the external coil is detected, the main control logic module records the starting reference of the coil. After the second joint signal is collected, the action arbitration state machine identifies the segment boundary of the coil. The spatiotemporal coordinate synchronization mapping module establishes independent trigger channels corresponding to the fixed-length cutting control unit and the bidirectional sorting and guiding control unit. When the physical point of the joint reaches the downstream cutting axis, the main control logic module schedules the fixed-length cutting control unit to output a fixed-length cutting drive pulse as a cutting control signal, and links the bidirectional sorting and guiding control unit to output a reversing control signal to the bidirectional electromagnetic reversing valve. This guides the transition wire section, including the joint and the range of 50.0 mm before and after it, into the waste collection path, completing the automatic coil cutting and spatiotemporal coordinate reloading in continuous wiring state.

[0073] In the physical layout along the wire transmission path, the joint detection sensing unit adopts a proximity sensing unit, rigidly positioned at the feed reference position 100.0mm upstream of the first detection station; the printhead module of the inkjet marking control unit is positioned 800.0mm downstream of the first detection station, with an inherent action delay constant calibrated to 1.2ms; the servo flying shear module of the fixed-length cutting control unit is positioned 1500.0mm downstream of the first detection station, with a servo response delay constant calibrated to 3.5ms. When the wire travels at a high speed of 10.0m / s, the fixed-length cutting control... The unit adopts a follow-up flying shear tracking mechanism. After receiving the cutting trigger signal, the servo motor drives the shearing blade to accelerate synchronously along the wire travel direction. Within the cutting range where the blade linear speed is the same as the wire running linear speed, the shear blade closes to complete the transverse cutting. After the cutting is completed, the blade decelerates and returns to the initial standby point. During the cutting action, the main control logic module synchronously links with the bidirectional sorting and guiding control unit, which outputs a reversing control signal to the bidirectional electromagnetic reversing valve to guide the joint transition section before and after cutting into the waste collection path, avoiding wire stacking jamming and tension instability caused by static cutting.

[0074] Example 4: This example combines Figures 1 to 2 This paper describes an integrated intelligent control system and method for testing the performance of metal wires, such as... Figure 1As shown, the motion and tension drive module drives the wire transmission and adjusts the wire's running linear speed and tension. The displacement pulse acquisition module acquires the wire displacement pulses and transmits them to the high-speed counting channel to accumulate and generate real-time absolute displacement coordinates, corresponding to step S1. The multi-station integrated detection sensor module acquires the multi-dimensional quality detection signals of the wire. When a quality state exceeds the limit, it outputs a state exceedance signal to the hardware interrupt capture interface. The hardware interrupt capture interface responds to the state exceedance signal, latching the microsecond timestamp of the detection time and the absolute displacement coordinates of the detection time, corresponding to step S2. The spatiotemporal coordinate synchronization mapping module calculates the distance between the absolute displacement coordinates of the detection time and the reference geometric distance of the target action unit. Calculate the remaining physical distance. Within the synchronous scanning cycle, calculate the real-time linear velocity and acceleration based on the pulse frequency change rate of the high-speed counting channel. Solve for the dynamic arrival time corresponding to the remaining physical distance and output the count value of the comparison register under sliding overload, corresponding to step S3. The multi-level task scheduling engine matches the output comparison register within the hard real-time interrupt and triggers the target action unit action of the end motion control module, corresponding to step S4. The torque feedforward decoupling module extracts the first derivative of the real-time linear velocity to generate an additional torque compensation amount. The additional torque compensation amount is superimposed and written into the torque register of the motion and tension drive module to suppress tension oscillations caused by wire speed fluctuations, corresponding to step S5.

[0075] like Figure 2 As shown, after performing on-site pre-calibration, the system establishes the initial measurement benchmark of the multi-station sensor signals and enters steady-state operation. During steady-state operation, when the actual action response lag time exceeds the preset safety limit, it switches to maintaining the constant-pass path and sends a device maintenance prompt signal while maintaining continuous operation and returning to steady-state operation. During steady-state operation, when an out-of-tolerance dimensional or cross-sectional distortion event is detected, it switches to generating a global scrap mark. Subsequently, when the action trigger time calculated by the sliding heavy load is reached, it switches to the scrap collection path. When the qualified wire section passes through, it maintains the constant-pass path and returns to steady-state operation. During steady-state operation, when the second connector signal input is detected, it switches to outputting a cut-off control signal and links the bidirectional sorting and guiding control unit to switch to the scrap collection path. During steady-state operation, when the bus communication is interrupted or a verification error occurs in the ring event queue, it switches to the constant-pass scrap isolation state. After triggering the fault state transfer arbitration mechanism and issuing a hardware safety reset level, it switches to executing controlled braking and stopping.

[0076] Example 5: This example uses a nominal diameter Using 4.00mm thick high-strength coiled alloy spring steel wire with a tensile strength benchmark of 850MPa, and considering the physical displacement equivalent drift caused by different batches of materials entering the system and the mechanical wear of the driven speed measuring wheel, the main control logic module performs a pre-calibration process during the system initialization and debugging phase. The motion and tension drive module drives the main traction motor to pull a standard fixed-length calibration strip through a 700mm benchmark physical interval between the first and second detection stations at a calibration linear speed of 1000mm / s. The displacement pulse acquisition module collects the accumulated orthogonal coded pulses within this interval and transmits them to the high-speed counting channel. When the measured pulse count is 7004 pulses, the main control logic module calculates the ratio of 700mm to 7004 pulses, obtaining 0.09994mm / pulse, and sets the physical displacement equivalent coefficient accordingly. The initial theoretical value of 0.10 mm / pulse is updated to 0.09994 mm / pulse and written into the system configuration register to eliminate the geometric deviation of the absolute displacement accumulation caused by the wear of the transmission wheel diameter. At the same time, the main control logic module sends a zero-level signal to the dual-axis laser diameter measurement unit and the cross-sectional profile scanning unit. Under no-load and unobstructed conditions, the dark level voltage noise of the optical sensor array is collected, and the zero-point offset is corrected when the standard 4.00 mm calibration sample is placed in the measurement light curtain. The calibration offset parameters are stored in the internal non-volatile storage area to establish the initial measurement benchmark of the multi-station sensing signal.

[0077] To address the hardware response delay drift caused by electromagnetic coil temperature rise and pneumatic pipeline resistance during long-term high-frequency operation of the end-effector control module, the main control logic module executes online feedback correction and safety interlocking procedures for the action lag time of the bidirectional sorting and guiding control unit during operation. A mechanical positioning detection sensor switch is installed at the sorting chute inlet of the diversion path, and the hard real-time interrupt control layer records a hardware timestamp of the control level output to the bidirectional electromagnetic reversing valve. Record the actual timestamp of receiving the commutation signal. The actual action response lag time is obtained by calculating the difference between the two values: ,in, This is the output timestamp for the control level of the bidirectional electromagnetic directional valve. This is the actual timestamp of the reversal signal. The actual action response lag time, when the time-space coordinate synchronization mapping module detects... When the actual action response lag time changes from the baseline value of 5.0ms to 6.2ms, this actual action response lag time is taken as the inherent action delay constant of the pneumatic sorting and guiding mechanism in the bidirectional sorting and guiding control unit. The new input variable is calculated and dynamically updated within a 1ms synchronous scan cycle to determine the action trigger time of subsequent defect events; when When the preset safety limit is exceeded by 8ms, the action arbitration state machine maintains the sorting slide in the normal open path and sends a device maintenance prompt signal to the monitoring terminal to avoid damage to the wires due to erroneous actions, while maintaining continuous operation of the system.

[0078] Example 6: This example uses a nominal diameter The high-strength coiled alloy spring steel wire is 4.00mm thick with a tensile strength benchmark of 850MPa. For the analog signal conversion and electrical noise filtering of the dynamic tension sensing unit, the main control logic module configures the sampling resolution of the analog input channel to 16 bits, with an input signal range of 4 to 20mA, corresponding to an internal digital register value of 0 to 27648. During the static calibration phase, standard weights of 0.0N, 250.0N, and 500.0N are sequentially suspended at the end of the tension detection wheel, and the corresponding sampled digital values ​​are read and processed according to… Calculate the linear calibration slope coefficient Then, the real-time sampled analog values ​​are converted into physical tension values. To suppress common-mode electromagnetic interference caused by the high-frequency carrier radiation of the main traction servo motor to the weak current sensing circuit, the deterministic synchronous scanning layer establishes a sliding sampling window with a depth of 8 cycles in each 1ms scanning cycle. The mean filtering of the 8 continuously acquired tension digital quantities is performed to filter out random pulse spikes, and the filtered tension feedback variable is sent to the torque feedforward decoupling module so that the tension closed-loop control word is continuously output when the wire travel tension is within the set working window.

[0079] To address the concurrent actions of the inkjet marking control unit, fixed-length cutting control unit, and bidirectional sorting and guiding control unit in the end-effector control module, as well as the overflow boundary of the hardware counter, the main control logic module sets up independent 32-bit output comparison registers for each target action unit in the field-programmable gate array expansion board, forming independent trigger channels corresponding to each target action unit. Each channel independently performs a decrementing comparison based on the target trigger pulse count value calculated by the spatiotemporal coordinate synchronization mapping module. The multi-level task scheduling engine matches the corresponding output comparison register within the hard real-time interrupt and triggers the corresponding target action unit action when the matching condition is met. To address the issue of the 32-bit pulse accumulator counter flipping back to zero due to prolonged high-speed operation of the main traction driven speed measuring wheel, the spatiotemporal coordinate synchronization mapping module uses unsigned integer modulo arithmetic when calculating the relative pulse difference between the current displacement and the target trigger displacement, quantizing the relative displacement into... To avoid interruption of spatiotemporal positioning calculations caused by counter flipping; at the same time, the main control logic module is equipped with a bus communication watchdog timer. When the industrial fieldbus communication interruption time exceeds the 10ms tolerance, or when a hardware read / write verification error occurs in the lockless ring event queue, the fault state transfer arbitration mechanism is triggered, and a hardware safety reset level is sent to the end motion control module, so that the bidirectional sorting and guiding control unit switches to the normally open waste isolation state, and controls the motion and tension drive module to perform controlled braking and stopping at a deceleration of -4000mm / s².

[0080] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0081] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. An integrated intelligent control system for testing the performance of metal wires, characterized in that, include: The main control logic module integrates a hardware interrupt capture interface, a high-speed counting channel, an output comparison register, a spatiotemporal coordinate synchronization mapping module, a multi-level task scheduling engine, a torque feedforward decoupling module, and a lock-free circular event queue. Motion and tension drive module, used to adjust the linear speed and tension of the wire; The displacement pulse acquisition module outputs displacement pulses to the high-speed counting channel to generate absolute displacement coordinates. The multi-station integrated detection and sensing module outputs a status out-of-bounds signal to the hardware interrupt capture interface; The end effector control module is deployed downstream to output action control signals; When a state out-of-bounds signal is received, the hardware interrupt capture interface latches the microsecond timestamp and absolute displacement coordinates; the spatiotemporal coordinate synchronization mapping module calculates the remaining distance based on the absolute displacement coordinates and the distance between the target action unit, calculates the linear velocity and acceleration based on the high-speed counting channel within the synchronization period, and solves the dynamic arrival time to slide the overload output comparison register; the multi-level task scheduling engine matches the output comparison register within the hard real-time interrupt to trigger the target action unit to act. The torque feedforward decoupling module extracts the first derivative of the linear velocity to generate an additional torque compensation amount, which is then written into the torque register to suppress tension oscillations.

2. The integrated intelligent control system for metal wire performance testing according to claim 1, characterized in that, The multi-level task scheduling engine constructs three mutually isolated task execution domains, including: the first layer is a hard real-time interrupt control layer with an execution cycle of 100μs and a clock jitter of less than 2μs, used to respond to hardware event matching of high-speed pulse capture, microsecond timestamp latching, emergency limit interlocking, and output comparison register; the second layer is a deterministic synchronous scanning layer with an execution cycle of 1ms, used to calculate multi-axis servo motion synchronization control algorithms, torque feedforward decoupling compensation, and periodic parsing of bus sensor messages; the third layer is an asynchronous data processing and status arbitration layer with an execution cycle of 5ms, used to complete multi-station quality data threshold comparison, out-of-tolerance event recording and packaging, and human-machine interaction communication; the main control logic module establishes a lockless circular event queue between the first and third layers for cross-layer transmission of action data packets containing action type codes, trigger target cycles, and unit physical addresses.

3. The integrated intelligent control system for metal wire performance testing according to claim 2, characterized in that, When a hardware interrupt occurs at the first level or a deterministic clock tick occurs at the second level, the multi-level task scheduling engine immediately protects and suspends the task context of the third level, prioritizing the allocation of processor computing power to respond to high-priority control tasks; after exiting the interrupt service routine, the computational flow of the third level is restored to block the jitter interference of multi-station concurrent detection data on the scanning cycle of the motion control loop.

4. The integrated intelligent control system for metal wire performance testing according to claim 1, characterized in that, The multi-station integrated detection sensing module includes a dynamic tension sensing unit; the torque feedforward decoupling module calculates the additional torque compensation based on the target tension setpoint, the feedback tension value sampled in real time by the dynamic tension sensing unit, and the first derivative of the real-time linear velocity. The additional torque compensation includes a feedforward component based on the product of the system rotational inertia feedforward compensation coefficient and the first derivative, and a closed-loop feedback component based on the proportional adjustment coefficient, integral adjustment coefficient and tension deviation. The main control logic module writes the calculated additional torque compensation into the torque feedforward channel of the motion and tension drive module in each 1ms synchronous scan cycle to eliminate the mechanical transmission inertial lag caused by traction speed variation in advance.

5. The integrated intelligent control system for metal wire performance testing according to claim 1, characterized in that, The multi-station integrated detection sensing module includes a dual-axis laser diameter measuring unit deployed at the first detection station; the dual-axis laser diameter measuring unit uses the nominal diameter of the wire as the central reference and sets the allowable range of symmetric tolerance to ±0.10mm; when the real-time acquired outer diameter measurement value exceeds the allowable range of symmetric tolerance, the main control logic module generates a dimensional deviation event and opens a tracking node for the corresponding physical segment of the wire in the unlocked ring event queue.

6. The integrated intelligent control system for metal wire performance testing according to claim 1, characterized in that, The multi-station integrated detection sensing module includes a cross-sectional profile scanning unit deployed at the second detection station; the cross-sectional profile scanning unit acquires the maximum and minimum outer diameters of the wire in the orthogonal direction in real time; the main control logic module calculates the percentage ratio of the absolute value of the difference between the maximum and minimum outer diameters to the nominal diameter to characterize the relative deformation rate of the cross section; when the relative deformation rate of the cross section is greater than 1.0%, the main control logic module triggers a cross-sectional distortion out-of-tolerance event, and performs spatiotemporal coordinate overlap and merging of the cross-sectional distortion out-of-tolerance event with the dimensional out-of-tolerance events already recorded in the same wire section in the unlocked ring event queue.

7. The integrated intelligent control system for metal wire performance testing according to claim 1, characterized in that, The end-point action control module includes a bidirectional sorting and guiding control unit, which contains a reversing control loop and a diversion path. The main control logic module maintains a normally open path when it determines that the multi-dimensional detection indicators of the corresponding physical section of the wire are all within the qualified set range. When any out-of-tolerance event is detected, a reversing level signal is output to the reversing control loop at the action trigger time calculated by the sliding heavy load, controlling the diversion channel to switch the unqualified wire section to the waste collection path.

8. The integrated intelligent control system for metal wire performance testing according to claim 1, characterized in that, The end-effector control module also includes an inkjet marking control unit and a fixed-length cutting control unit; the spatiotemporal coordinate synchronization mapping module constructs independent trigger channels corresponding one-to-one with the inkjet marking control unit, the fixed-length cutting control unit, and the bidirectional sorting guide control unit according to the reference installation spacing of each unit along the transmission path; when a defect is detected, the main control logic module controls the inkjet marking control unit to output a color mark drive signal when the corresponding defect point reaches the marking position, and triggers the sorting action after the defect section enters the sorting interval.

9. The integrated intelligent control system for metal wire performance testing according to claim 8, characterized in that, The multi-station integrated detection sensing module also includes a joint detection sensing unit; the main control logic module monitors the joint signal and records the segment position of the material in the tray. When the second joint signal input is detected, the fixed-length cutting control unit is scheduled to output a cutting control signal and link the bidirectional sorting and guiding control unit to guide the joint waste into the waste collection path to complete the automatic tray sorting.

10. An integrated intelligent control method for testing the performance of metal wires, applied to the integrated intelligent control system for testing the performance of metal wires as described in claim 1, characterized in that, Includes the following steps: Step S1: The motion and tension drive module drives the wire transmission and adjusts the wire's running linear speed and tension; the displacement pulse acquisition module acquires the wire displacement pulses and transmits them to the high-speed counting channel to accumulate and generate real-time absolute displacement coordinates. Step S2: The multi-station integrated detection sensor module collects multi-dimensional quality detection signals of the wire. When the quality status exceeds the limit, it outputs a status exceedance signal to the hardware interrupt capture interface. The hardware interrupt capture interface responds to the status exceedance signal and latches the microsecond timestamp of the detection time and the absolute displacement coordinate of the detection time. Step S3: The spatiotemporal coordinate synchronization mapping module calculates the remaining physical distance based on the absolute displacement coordinates at the detection time and the reference geometric distance between the target action unit. During the synchronous scanning cycle, it calculates the real-time linear velocity and acceleration based on the pulse frequency change rate of the high-speed counting channel. It then calculates the dynamic arrival time corresponding to the remaining physical distance and outputs the count value of the comparison register under sliding overload. Step S4: The multi-level task scheduling engine matches the output comparison register within the hard real-time interrupt and triggers the target action unit action of the end action control module. In step S5, the torque feedforward decoupling module extracts the first derivative of the real-time linear velocity to generate an additional torque compensation amount, and then superimposes the additional torque compensation amount into the torque register of the motion and tension drive module to suppress tension oscillations caused by wire speed fluctuations.

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