A sports cable selection system and method

Abstract

The application discloses a motion cable selection system and method, wherein the system comprises: a data acquisition layer for acquiring working condition parameters input by a user end, and acquiring a damage reference value corresponding to the working condition parameters from a damage accumulation model; a decision engine for performing multi-level matching according to the working condition parameters and the damage reference value, and determining a cable selection scheme corresponding to the working condition parameters; and a scheme output layer for outputting the cable selection scheme, and outputting manufacturing process parameters corresponding to the cable selection scheme to a manufacturing end. The application scheme realizes the change of motion cable selection from artificial experience judgment to full-process automation and standardized decision-making through structured parameter conversion, multi-level automatic matching decision and direct output of manufacturing process parameters, and continuously improves the selection accuracy in combination with the data linkage of the damage accumulation model and the feedback loop of the manufacturing use result.

Description

Technical Field

[0001] This application relates to the field of cable selection technology, specifically to a system and method for selecting motion cables. Background Technology

[0002] Motion cables are widely used in CNC machine tools, industrial automation, crane drums and other fields. Their service life and stability directly determine whether the equipment operates normally.

[0003] Currently, the selection of motion cables relies heavily on manual experience. Users need to comprehensively assess various operating conditions, including motion type, bending radius, reciprocating speed and acceleration, torsional angle and angular velocity, ambient temperature and humidity, oil and corrosive media, voltage level and current capacity, and installation space constraints, to determine the required cable flexibility, conductor structure, insulation material, shielding structure, sheath material, and relevant product certifications. These parameters are interrelated and mutually restrictive. Manual selection requires repeatedly consulting multiple standard documents and product manuals, verifying each parameter to ensure it meets requirements. Omission of any constraint or misjudgment of a parameter can lead to a mismatch between the selected cable and the actual operating conditions. Undersized cables, insufficient flexibility, or incompatible materials can cause cable malfunctions such as core breakage, sheath cracking, and shielding failure during operation, resulting in equipment downtime, rework, cable replacement, and even production line shutdowns.

[0004] At cable manufacturing plants, conductor stranding grades, insulation materials, sheath materials, shielding structures, and tensile strength designs vary depending on the application scenario, lacking a unified selection standard. New employees struggle to independently complete compliant selections, and the company's process knowledge relies heavily on the personal experience of a few senior staff, hindering systematic accumulation and transmission. Furthermore, domestic and international standards are used interchangeably, resulting in numerous certification types. The selection process requires verifying each product's compliance with the target market's certification requirements, a labor-intensive process prone to oversights.

[0005] While some general-purpose cable selection software exists in the existing technology, these tools are mainly designed for current carrying capacity, voltage level, and material selection in fixed laying scenarios. They cannot handle selection needs under dynamic working conditions such as cable chain movement, reciprocating bending, and torsion, and are not suitable for application scenarios of moving cables.

[0006] In summary, the existing methods for selecting motion cables have the following shortcomings: manual selection requires repeated weighing and verification among multi-dimensional operating parameters, which is inefficient and prone to overlooking key constraints; selection knowledge relies on personal experience and lacks a standardized and reusable decision-making system; general selection software cannot adapt to dynamic motion conditions; and the selection results cannot be directly linked to the production and manufacturing process, requiring additional manual conversion between selection completion and actual production. Summary of the Invention

[0007] This application addresses the industry pain points of existing manual selection methods that rely on experience, have incomplete verification, and lack a standardized decision-making system. It provides a motion cable selection system and method that achieves fully automated and intelligent selection of motion cables through structured parameter analysis, multi-level matching decision-making, and manufacturing process output.

[0008] To address the aforementioned issues, the method provided in this application is as follows:

[0009] In a first aspect, this application provides a sports cable selection system, the system comprising:

[0010] The data acquisition layer is used to acquire the operating condition parameters input by the user terminal, and to obtain the damage reference values ​​corresponding to the operating condition parameters from the damage accumulation model.

[0011] The decision engine is used to perform multi-level matching based on the operating condition parameters and the damage reference value to determine the cable selection scheme corresponding to the operating condition parameters;

[0012] The solution output layer is used to output the cable selection solution and output the manufacturing process parameters corresponding to the cable selection solution to the manufacturing end.

[0013] Preferably, the data acquisition layer includes:

[0014] The parameter parsing module is used to convert the operating condition parameters input by the user into structured parameters;

[0015] The data interface module is used to read selection rule data from the knowledge base and to read the damage reference value corresponding to the structured parameter from the damage accumulation model.

[0016] Preferably, the decision engine includes:

[0017] The flexibility level determination module is used to determine the flexibility level of the cable based on the structured parameters and the damage reference value;

[0018] A material matching module is used to match the material and structure of the cable according to the structured parameters and the flexibility level;

[0019] The compliance matching module is used to match the corresponding product certification standards based on the certification requirements in the structured parameters.

[0020] Preferably, the solution output layer includes:

[0021] The user-end output module is used to output the cable selection scheme, which includes at least one of the following: flexibility level, model and specifications, material of each layer, electrical parameters, certification information and expected cycle life.

[0022] The manufacturing output module is used to output the manufacturing process parameters, which include at least one of the following: bill of materials, process flow, and process parameters.

[0023] Preferably, the system further includes:

[0024] The feedback layer is used to obtain the manufacturing results corresponding to the cable selection scheme and update the knowledge base and / or damage accumulation model based on the results.

[0025] Secondly, a method for selecting motion cables, the method comprising:

[0026] Obtain the operating condition parameters input by the user;

[0027] Obtain the damage reference value corresponding to the operating condition parameter from the damage accumulation model;

[0028] Based on the operating parameters and the damage reference values, a multi-level matching process is performed to determine the cable selection scheme.

[0029] Output the cable selection scheme and output the manufacturing process parameters corresponding to the cable selection scheme to the manufacturing end.

[0030] Preferably, the acquisition of operating condition parameters input by the user terminal includes:

[0031] Convert the operating condition parameters in natural language format, structured form format, or historical model format into unified structured parameters.

[0032] Preferably, the multi-level matching includes:

[0033] The flexibility level is determined based on the structured parameters and the damage reference values;

[0034] The material and structure are matched according to the structuring parameters and the flexibility level;

[0035] Match product certification standards to the certification requirements in the structured parameters.

[0036] Preferably, determining the cable selection scheme includes:

[0037] Output user-side selection solutions and manufacturing-side process solutions;

[0038] The user terminal selection scheme includes at least one of the following: flexibility level, model specifications, material of each layer, electrical parameters, certification information, and expected cycle life;

[0039] The manufacturing process plan includes at least one of a bill of materials, a process flow, and process parameters.

[0040] Preferably, the method further includes:

[0041] Obtain the manufacturing results corresponding to the cable selection scheme;

[0042] Update at least one of the knowledge base and / or the damage accumulation model based on the results.

[0043] The beneficial effects of this application are as follows:

[0044] This invention acquires operating condition parameters input from the user end and converts them into structured parameters. Combined with damage reference values ​​provided by a damage accumulation model, it performs multi-level decision-making, including flexibility level determination, material and structure matching, and compliance matching. It outputs a selection scheme and corresponding manufacturing process parameters, and updates the decision-making basis based on manufacturing and usage feedback, forming a closed loop of selection-manufacturing-feedback. This automates and standardizes the selection of motion cables, effectively reducing the complexity and trial-and-error costs of manual selection, while bridging the gap between selection results and production manufacturing.

[0045] Instruction manual illustrations

[0046] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0047] Figure 1 This is a schematic diagram of the overall architecture of the motion cable selection system provided in the embodiments of this application.

[0048] Figure 2 This is a structural block diagram of the data acquisition layer provided in an embodiment of this application.

[0049] Figure 3 This is a structural block diagram of the decision engine provided in the embodiments of this application.

[0050] Figure 4 This is a structural block diagram of the output layer of the solution provided in the embodiments of this application.

[0051] Figure 5 This is a flowchart illustrating the motion cable selection method provided in an embodiment of this application.

[0052] Figure 6 This is a schematic diagram illustrating the working principle of the feedback layer provided in the embodiments of this application.

[0053] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0054] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0055] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, components, features, and elements with the same names in different embodiments of this application may have the same meaning or different meanings, the specific meaning of which must be determined by its interpretation in that specific embodiment or further in conjunction with the context of that specific embodiment.

[0056] It should be understood that although the terms first, second, third, etc., may be used herein to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this document, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if," as used herein, may be interpreted as "when," "when," or "in response to determination." Furthermore, as used herein, the singular forms "a," "an," and "the" are intended to also include the plural forms unless the context indicates otherwise. It should be further understood that the terms "comprising," "including," indicate the presence of the stated feature, step, operation, element, component, item, kind, and / or group, but do not exclude the presence, occurrence, or addition of one or more other features, steps, operations, elements, components, items, kinds, and / or groups. The terms "or," "and / or," "including at least one of the following," etc., as used in this application, may be interpreted as inclusive, or mean any one or any combination thereof. For example, "including at least one of the following: A, B, C" means "any one of the following: A; B; C; A and B; A and C; B and C; A and B and C." Similarly, "A, B, or C" or "A, B, and / or C" means "any one of the following: A; B; C; A and B; A and C; B and C; A and B and C." Exceptions to this definition only occur when the combination of elements, functions, steps, or operations is inherently mutually exclusive in some way.

[0057] It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit this application.

[0058] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrative purposes and has no specific meaning in itself. Therefore, "module," "part," or "unit" may be used interchangeably.

[0059] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0060] refer to Figure 1 As shown in the embodiment of this application, the sports cable selection system includes: a data acquisition layer, a decision engine, a solution output layer, and a feedback layer.

[0061] In the embodiments of this application, the system of this application acquires the operating condition parameters input by the user terminal through the data acquisition layer, and acquires the damage reference value corresponding to the operating condition parameters from the damage accumulation model; the system performs multi-level matching of the acquired operating condition parameters and damage reference values ​​through the decision engine to determine the cable selection scheme corresponding to the operating condition parameters; the system further outputs the cable selection scheme through the scheme output layer, and outputs the manufacturing process parameters corresponding to the cable selection scheme to the manufacturing end.

[0062] The system solution provided in this application realizes the transformation of motion cable selection from manual experience judgment to fully automated and standardized decision-making through structured parameter conversion, multi-level automatic matching decision-making, and direct output of manufacturing process parameters. Furthermore, by combining data linkage of the damage accumulation model with feedback loop of manufacturing and usage results, the accuracy of selection is continuously improved.

[0063] refer to Figure 2 As shown, the data acquisition layer in this embodiment includes a parameter parsing module and a data interface module. The parameter parsing module converts the operating condition parameters input by the user terminal into structured parameters. In this embodiment, the user terminal input methods include at least the following three:

[0064] Natural language input method: Users input their work requirements in a conversational manner, such as "servo power cables exported to the United States, used in the reciprocating motion of machine tool X-axis cable carriers". The parameter parsing module uses natural language processing technology to perform entity recognition (identifying standard names, parameter values ​​and units) and context disambiguation (determining the scope and priority of the standard based on the context) on the input text, extracting key information from the natural language and converting it into standard structured parameters.

[0065] Structured form input method: Users fill in or select parameter values ​​in the corresponding fields through a preset form interface. For example, selecting "drag chain" in the "Motion Type" field and entering "60mm" in the "Bending Radius" field. The parameter parsing module directly reads the form data and performs data compliance verification (checking data type, unit, and value range).

[0066] Historical model reverse parsing method: The user inputs an existing cable model, and the parameter parsing module reverse-parses the corresponding parameters of the model based on the model-parameter mapping relationship stored in the knowledge base, which serves as a reference for model selection.

[0067] The operating parameters obtained through the above methods are converted into a unified standardized parameter vector after data compliance verification and output to the decision engine.

[0068] The data interface module is used to read selection rule data from the knowledge base and the damage reference value corresponding to the structured parameter from the damage accumulation model. In this embodiment, the knowledge base stores various rule data required for selection, including: for example, flexibility level determination rule data: defining the flexibility level mapping relationship corresponding to different motion forms, bending ratios, and cycle lives; for example, material matching rule data: defining the screening logic for conductors, insulation, shielding, sheathing, and other materials under different operating conditions; and for example, compliance mapping rule data: defining the correspondence between different certification standards and cable structural parameters. In this embodiment, the knowledge base is constructed as follows: based on industry standards (such as UL, IEC, and GB standards), historical test data from enterprises, and historical selection cases, rules are extracted and verified by domain experts before being stored in the knowledge base. The knowledge base adopts a rule effectiveness grading mechanism—mandatory rules (such as safety certification requirements), recommended rules (such as material selection suggestions), and reference rules (such as cost optimization suggestions), with different levels of rules having different weights in decision-making.

[0069] In this embodiment, the damage accumulation model originates from the applicant's patent application "A Cable Dynamic Monitoring System and Method" filed on the same day. This model calculates the cumulative damage value based on dynamic parameters such as the cable's bending radius, motion frequency, and tensile amplitude, and outputs the cable's health status and remaining service life. The data interface module calls this model via an API interface, taking the structured parameters (motion type, bending radius, expected number of cycles, etc.) corresponding to the current operating conditions as input. The model returns a reference value for the expected cumulative damage rate of the cable under these operating conditions, and uses this damage reference value as one of the important input parameters for determining the flexibility level.

[0070] refer to Figure 3 As shown, the decision engine in this embodiment includes a flexibility level determination module, a material matching module, and a compliance matching module.

[0071] The flexibility rating determination module is used to determine the flexibility rating of the cable based on structured parameters and damage reference values. In this embodiment, the flexibility rating includes, but is not limited to: ordinary flexibility, high flexibility, ultra-high flexibility, and torsional flexibility. The definitions of each rating are as follows:

[0072] Ordinary flexible: Suitable for cable carriers or reciprocating motion scenarios with a large bending ratio (≥10 times the cable outer diameter) and a small number of cycles (≤5 million times);

[0073] High flexibility: Suitable for cable chain motion scenarios with medium bending ratio (6-10 times the cable outer diameter) and medium cycle count (5-10 million times);

[0074] Ultra-high flexibility: Suitable for high-speed cable chain motion scenarios with small bending ratios (≤6 times the cable outer diameter) and high cycle counts (≥10 million times);

[0075] Torsional flexibility: Suitable for scenarios that require torsional motion, such as robot joints and wind turbine pitch control.

[0076] When determining the flexibility level, an exemplary logic is adopted as follows:

[0077] First, the main category is determined based on the motion form in the structured parameters—drag chain motion, torsion motion, or winding motion.

[0078] Secondly, based on the bending ratio (the ratio of the minimum bending radius to the estimated outer diameter of the cable) and expected cycle life in the structured parameters, the sub-level under this main category is determined. The smaller the bending ratio and the higher the expected cycle life, the higher the corresponding flexibility level.

[0079] Finally, the damage reference value returned by the damage accumulation model is used as a correction factor—if the damage reference value indicates that the expected damage rate of the cable under this condition is high, the flexibility level is appropriately increased (e.g., from ordinary flexibility to high flexibility); otherwise, the flexibility level is maintained or reduced.

[0080] The material matching module is used to match the cable's material and structure based on the structural parameters and the aforementioned flexibility level. In this embodiment, an exemplary logic for material matching is as follows:

[0081] (1) Conductor matching: Based on the electrical parameters (voltage, current) and flexibility level in the structured parameters, select conductor material (bare copper, tin-plated copper, silver-plated copper), conductor structure (Category 5 stranding, Category 6 ultra-fine stranding) and conductor cross-section. The higher the flexibility level, the smaller the diameter of the stranded wire and the more strands there are, under the premise of the same cross-sectional area.

[0082] (2) Insulation matching: Based on the temperature requirements, oil resistance requirements and voltage levels in the structural parameters, select the insulation material (PVC, PE, PP, fluoroplastics, etc.) and insulation thickness. Use insulation materials with higher temperature resistance for high-temperature environments and oil-resistant insulation materials for oily environments.

[0083] (3) Shielding matching: Based on the electromagnetic compatibility requirements and flexibility level in the structured parameters, select the shielding structure (braided shielding, spiral shielding, aluminum foil shielding, etc.) and shielding density. For scenarios with high requirements for low-frequency signal transmission performance, use tin-plated copper wire braided shielding with a braiding density ≥85%.

[0084] (4) Sheath matching: Based on the environmental factors (temperature, oil, corrosion, abrasion resistance requirements) and flexibility level in the structural parameters, select the sheath material (PVC, TPU, neoprene, etc.) and sheath thickness. Use oil-resistant sheaths for oily environments and cold-resistant sheaths for low-temperature environments.

[0085] In this embodiment, the material matching module outputs at least one set of matching results in descending order of matching score. In a preferred embodiment, 2-3 sets of alternative solutions can be calculated in parallel and output for the user to select, with each solution labeled with a matching score and a description of performance differences.

[0086] The compliance matching module is used to match the corresponding product certification standards based on the certification requirements in the structured parameters. In this embodiment, certification requirements include, but are not limited to: UL certification (USA), CE certification (Europe), CCC certification (China), VDE certification (Germany), etc. An exemplary logic for compliance matching is as follows:

[0087] First, the target certification standard is determined based on the certification requirements in the structured parameters. When the certification requirements entered by the user are unclear (such as only entering "Export to the United States" without specifying a specific standard), the compliance matching module automatically identifies them according to the mapping rules in the knowledge base—for example, "Export to the United States" is mapped to UL certification.

[0088] Secondly, based on the determined flexibility level and material structure matching results, the model that meets the target certification standard is searched in the knowledge base. The compliance matching module has a built-in certification mapping table that maps cable structural parameters (conductor material, insulation material, shielding structure, sheath material, voltage level) one-to-one with the model in the certification standard.

[0089] When a user requests certifications from multiple countries (e.g., "meeting both UL and CE certifications simultaneously"), the conflict resolution unit of the compliance matching module processes the request according to a preset standard effectiveness grading mechanism. First, it checks if there is a model that meets multiple certifications simultaneously. If not, it selects the model according to the user's preset priority (mandatory / bonus items), prioritizing the mandatory certification.

[0090] In this embodiment, the compliance matching module also has a built-in standard version management mechanism that records the effective date and expiration date of each certification standard to ensure that the selection result conforms to the currently valid version. When it is detected that the standard version specified by the user has been deprecated, it automatically upgrades to the latest valid version and prompts the user.

[0091] refer to Figure 4 As shown, the output layer of the solution in this embodiment includes a user-end output module and a manufacturing-end output module.

[0092] The user-end output module is used to output cable selection schemes, which include at least one of the following: flexibility level, model specifications, material of each layer, electrical parameters, certification information, and expected cycle life.

[0093] In one embodiment, the selection scheme output by the user terminal includes the following:

[0094] Flexibility levels: Ordinary flexibility / High flexibility / Ultra-high flexibility / Torsional flexibility;

[0095] Product Model: Model code automatically generated by the system;

[0096] Conductor specifications: material, structure (number of strands × diameter of single wire), cross-sectional area;

[0097] Insulation specifications: material, thickness, temperature rating;

[0098] Shielding specifications: material, structure, shielding method, shielding effectiveness;

[0099] Sheath specifications: material, thickness, temperature resistance rating, oil resistance rating;

[0100] Electrical parameters: rated voltage, withstand voltage rating;

[0101] Certification information: Applicable certification standards and models;

[0102] Expected cycle life: The number of cycles that can be supported under current operating conditions (with confidence interval).

[0103] Physical parameters: finished product outer diameter, cable weight;

[0104] Selection decision criteria: rule number, matching reason, and confidence level for each matching result.

[0105] The manufacturing output module is used to output manufacturing process parameters, which include at least one of a bill of materials, a process flow, and process parameters. In one embodiment, the process plan output by the manufacturing end includes the following:

[0106] Bill of Materials (BOM): The type, specifications, and quantity of materials used in each layer;

[0107] Process flow: Wire drawing → Stranding → Insulation extrusion → Cable forming → Braiding → Sheath extrusion → Inspection;

[0108] Process parameters:

[0109] Conductor stranding: stranding direction, stranding pitch, stranding ratio, single wire diameter, number of single wires, number of strands in the bundle, and outer diameter of the strand;

[0110] Insulation extrusion: extrusion temperature, extrusion speed, insulation thickness, insulation material, insulation color, insulation outer diameter and tolerances;

[0111] Cable forming: cable forming direction, cable forming pitch, cable forming coefficient, core wire arrangement, cable outer diameter, and filler material;

[0112] Weaving: Weaving yarn diameter, weaving density, weaving angle, number of weaving spindles, weaving pitch, weaving outer diameter;

[0113] Sheath extrusion: extrusion temperature, extrusion speed, sheath thickness, sheath material, sheath color, finished product outer diameter and tolerance;

[0114] In addition, work instructions: key points of operation and quality control standards for each process.

[0115] The above process parameters are further generated using the following exemplary logic:

[0116] The conductor stranding ratio is calculated based on the conductor structure (number of strands × diameter of single wire) and the stranding pitch. The formula for calculating the stranding ratio λ is: Where D is the outer diameter of the strand and h is the strand pitch.

[0117] The insulation embedding factor is determined based on the flexibility of the insulation material and the extrusion process. It reflects the degree of embedding of the insulation layer during the cabling process and typically ranges from 1.01 to 1.05.

[0118] The cabling coefficient is calculated based on the outer diameter of the cable and the cable pitch, and is used to determine the outer diameter of the cable core after cabling.

[0119] In this embodiment, the specific values ​​of the above process parameters are automatically generated based on the material, structure and specifications in the selection results, ensuring that the manufacturing end can directly carry out production according to the output process plan.

[0120] The feedback layer in this application embodiment employs the following exemplary working mechanism:

[0121] (1) Manufacturing Data Feedback: During the cable manufacturing process, actual process parameters (such as actual stranding rate, actual insulation thickness, actual sheath thickness, etc.) and finished product inspection data (such as yield rate, electrical performance test results) are collected. The feedback layer compares the actual process parameters with the standard process parameters output by the scheme and analyzes the impact of deviations on cable performance. When the actual manufacturing data shows that a certain process parameter has a significant impact on cable performance, the feedback layer triggers the update of the confidence of the corresponding rule in the knowledge base—if the actual production verifies the accuracy of a rule, the confidence weight of the rule is increased; if it is found that a rule causes a large deviation between the selection result and the actual manufacturing effect, the confidence weight of the rule is reduced and manual review is prompted.

[0122] (2) User-side data feedback: After the cable is put into use, the actual operating data (including resistance changes, temperature, motion status, etc.) and health assessment results of the cable are obtained through the cable dynamic monitoring system described in the third application. The feedback layer compares the actual service life of the cable with the expected cycle life predicted in the selection scheme. If the actual service life is significantly lower than the predicted value, it indicates that the selection rules are too optimistic and the flexibility level judgment threshold under the corresponding working conditions needs to be adjusted. If the actual service life is significantly higher than the predicted value, it indicates that the selection rules are too conservative and the judgment conditions can be appropriately relaxed to optimize costs.

[0123] (3) Damage accumulation model calibration: The cumulative damage data monitored during the actual use of the cable is fed back to the damage accumulation model to correct the model parameters. The feedback layer compares the actual damage evolution curve with the model prediction curve, analyzes the source of deviation, and adjusts the damage accumulation coefficient in the model through parameter inversion method to gradually improve the prediction accuracy of the model.

[0124] In this embodiment, the above-mentioned feedback mechanism constitutes a complete closed loop from "selection → manufacturing → use → feedback → optimized selection", which enables the accuracy of the selection system to continuously improve with the accumulation of data.

[0125] refer to Figure 5 As shown in the embodiment of this application, a method for selecting sports cables includes:

[0126] S1. Obtain the operating condition parameters input by the user.

[0127] In this embodiment, the operating condition parameters input by the user are obtained through the data acquisition layer. The user input methods include natural language input, structured form input, and reverse parsing of historical models. After processing by the parameter parsing module, these parameters are converted into unified structured parameters. In one embodiment, the structured parameters include, but are not limited to, the following five categories:

[0128] (1) Electrical parameters: voltage, current, frequency, whether shielding is required;

[0129] (2) Motion parameters: motion type (drag chain / twist / winding), bending radius, reciprocating speed, reciprocating acceleration, twisting angle, twisting angular velocity;

[0130] (3) Environmental parameters: operating temperature range, whether it comes into contact with oil, whether it comes into contact with corrosive media, humidity;

[0131] (4) Installation parameters: cable chain length, stroke, and installation space constraints;

[0132] (5) Life requirements: expected number of cycles and maintenance cycle.

[0133] S2. Obtain damage reference values ​​from the damage accumulation model.

[0134] In this embodiment, the current structured parameters are used as input through the data interface module to call the API interface of the damage accumulation model and obtain the reference value of the expected cumulative damage rate of the cable under this working condition.

[0135] The damage accumulation model is derived from the applicant's patent application "A Cable Dynamic Monitoring System and Method" filed on the same day. This model calculates the cumulative damage value based on dynamic parameters such as the cable's bending radius, motion frequency, and tensile amplitude. In this step, the selection system inputs the motion type, bending radius, and expected number of cycles from the operating condition parameters into the model. The model returns a reference value for the damage rate under this operating condition, which is used for correction calculations in subsequent flexibility level determination.

[0136] S3, multi-level matching decision.

[0137] In this embodiment, after obtaining the damage reference, multi-level matching is further performed using structured parameters obtained through transformation to determine the cable selection scheme. (Reference) Figure 6 As shown, an exemplary procedure for determining a cable selection scheme is as follows:

[0138] S31, Flexibility level determination.

[0139] In this embodiment, the main classification is determined based on the motion pattern in the structured parameters, the sub-class is determined based on the bending ratio and expected cycle life, and the damage reference value returned by the damage accumulation model is used as a correction factor to finally determine the flexibility level of the cable.

[0140] Specifically, the bending ratio is first calculated: Bending ratio = Minimum bending radius / Estimated cable outer diameter. The estimated outer diameter is read from an empirical data table in the knowledge base based on electrical parameters (voltage level, number of cores, cross-section).

[0141] Then, select the corresponding decision table based on the motion pattern, for example:

[0142] Cable chain movement: Bending ratio ≥ 10 and expected life ≤ 5 million cycles → ordinary flexibility; Bending ratio 6-10 and expected life 5-10 million cycles → high flexibility; Bending ratio ≤ 6 and expected life ≥ 10 million cycles → ultra-high flexibility.

[0143] Torsional motion: directly judged as torsional flexibility.

[0144] Winding motion: The flexibility level is determined based on the winding speed and the number of windings.

[0145] Finally, adjustments are made based on the damage reference value: if the damage reference value is higher than the historical average level for similar working conditions, the flexibility level is increased by one level (e.g., ordinary flexibility → high flexibility); if the damage reference value is lower than the historical average level, the original level is maintained.

[0146] S32, Material and structure matching.

[0147] In this embodiment, the materials and structures of the conductor, insulation, shielding, and sheath are matched sequentially based on the structured parameters and flexibility level. Material matching employs a multi-dimensional screening and scoring ranking method. Each dimension (electrical performance, mechanical performance, environmental adaptability, and cost) is assigned different weights, and each candidate material is comprehensively scored, with the results output in descending order of score.

[0148] S33, Compliance matching.

[0149] In this embodiment, the corresponding product certification standards are further matched based on the certification requirements in the structured parameters. The specific process for compliance matching is as follows: parsing certification requirements → searching the certification mapping table → matching models that meet the certification requirements → outputting certification information. When there are certification requirements from multiple countries and no single model can simultaneously meet them, a conflict resolution mechanism is activated, prioritizing mandatory requirements.

[0150] S4. Output selection scheme and manufacturing process parameters.

[0151] In the embodiments of this application, after determining the cable selection scheme through the above steps, the user-end selection scheme is output, and the manufacturing process parameters corresponding to the cable selection scheme are output to the manufacturing end. The user-end selection scheme includes: flexibility level, product model, material specifications for each layer, electrical parameters, certification information, expected cycle life (with confidence interval), physical parameters, and selection decision basis. The manufacturing end process scheme includes: bill of materials (BOM), process flow, process parameters for each process (including tolerance range), and work instructions.

[0152] S5, data feedback closed-loop optimization.

[0153] In the embodiments of this application, the manufacturing results and / or usage results of the cables corresponding to the cable selection scheme are further obtained, and the knowledge base and / or damage accumulation model are updated based on the manufacturing results and / or usage results. Specifically, manufacturing result feedback involves collecting actual process parameters and yield rates, analyzing the impact of deviations, and updating the confidence weights of rules in the knowledge base. Usage result feedback involves obtaining actual operating data and health status through a cable dynamic monitoring system, comparing the actual lifespan with the predicted lifespan, and adjusting the flexibility level determination threshold. Damage accumulation model calibration involves feeding actual damage evolution data back to the model, correcting model parameters, and improving prediction accuracy.

[0154] Example: Selection of servo power cables for export to the United States

[0155] In this example, the user inputs: "Servo power cable for export to the United States, 4 cores 16AWG, used in the X-axis cable chain reciprocating motion of a machine tool, cable chain length 1.2m, running speed 0.8m / s, the equipment runs continuously for 8 hours a day, the cable will be exposed to oily environments, the cable temperature during startup should not exceed 100℃, the minimum bending radius is 60mm, the equipment maintenance period is 6 months, and the cable must not be damaged during the maintenance period."

[0156] The structured parameters are obtained by parsing the operating parameters, as shown below:

[0157] Export to the United States → Certification Requirements: UL Certification

[0158] Machine tool X-axis cable chain reciprocating motion → Motion type: cable chain

[0159] Cable chain length 1.2m, speed 0.8m / s → short stroke, low speed

[0160] Cable chain length 1.2m, speed 0.8m / s, 8 hours per day, 6-month maintenance period → Expected cycle life = (40 cycles / minute × 60 minutes × 8 hours × 30 days × 6 months) = 3,456,000 cycles

[0161] American-made servo power cables → 480V, shielding required

[0162] Oily environments → Oil resistance requirements

[0163] Start-up overheating not exceeding 100℃ → Maximum operating temperature 100℃

[0164] 4-core 16AWG, minimum bending radius 60mm → estimated outer diameter 8.3mm, bending ratio = 60 / 8.3≈7.2 times.

[0165] Flexibility level determination:

[0166] Cable chain + short stroke + low speed + 3.456 million cycles + 7.2 times bending ratio → ordinary flexibility.

[0167] Perform material and structure matching:

[0168] UL certification → Materials that meet UL standards.

[0169] Ordinary flexible + shielding + oil resistant → Class 6 soft copper conductor + 105℃ PVC insulation + tinned copper wire braided shielding + 105℃ oil resistant PVC sheath.

[0170] 480V → Insulation and sheath thickness matching 600V withstand voltage rating.

[0171] Perform compliance matching:

[0172] UL certified + PVC insulation + shielding + PVC sheath + 480V voltage → Style2586.

[0173] Output the cable selection scheme for the user end:

[0174] Flexibility level: Ordinary flexibility

[0175] Model: Flex-UQF111.04.16AWG

[0176] Specifications: 4×16AWG

[0177] Conductor: Category 6 ultrafine stranded bare copper

[0178] Insulation: Polyvinyl chloride (105℃)

[0179] Shielding: Tinned copper wire braid (braiding density ≥ 85%)

[0180] Sheath: Oil-resistant polyvinyl chloride (105℃)

[0181] Voltage rating: 600V

[0182] UL Certification: Style 2586

[0183] Expected cycle life: Up to 5 million cycles under current operating conditions (confidence range ±20%)

[0184] Cable reference weight: 136kg / km

[0185] Finished product reference outer diameter: 8.9±0.3mm

[0186] Selection criteria: Rule UL758 (UL certified PVC insulated shielded cable matching rule), 95% confidence level.

[0187] Based on the above user-end cable selection scheme, the final manufacturing process parameters are determined and output as follows:

[0188]

[0189] In the embodiments of this application, the damage accumulation model involved in this application is derived from the applicant's patent application filed on the same day entitled "A Cable Dynamic Monitoring System and Method," the entire contents of which are incorporated herein by reference. The cable structure with deformation sensing function involved in this application is described in the applicant's patent application filed on the same day entitled "A Wrapped Deformation Sensing Dynamic Monitoring Cable," the entire contents of which are incorporated herein by reference. When the user's selection scheme includes a monitoring function, the material matching module automatically configures a deformation sensing structure containing a sensing metal core wire in the cable structure. When the scheme output layer outputs to the manufacturing end, it automatically retrieves and binds the monitoring core wire embedding process control parameters adapted to the deformation sensing structure.

[0190] In summary, through the above-disclosed technical solutions, this application has at least the following beneficial effects:

[0191] (1) By obtaining operating parameters through the data acquisition layer and obtaining damage reference values ​​from the damage accumulation model, the selection decision and the actual operation damage data of the cable are linked, thus improving the accuracy of the selection.

[0192] (2) The decision engine performs multi-level automatic decision-making for flexibility level determination, material structure matching and compliance matching, which replaces manual experience selection and realizes the standardization and automation of the selection process.

[0193] (3) The solution output layer outputs the user-end selection scheme and the manufacturing process parameters at the same time, which connects the entire process from selection to production and eliminates the information gap between the selection result and the manufacturing execution.

[0194] (4) By feeding the manufacturing results and usage results back to the knowledge base and damage accumulation model through the feedback layer, the continuous optimization of the selection rules and the closed-loop iteration of the model are realized.

[0195] (5) By linking with the damage accumulation model, the selection results can be dynamically calibrated based on actual operating data, which improves the scientificity and reliability of the selection.

[0196] (6) By directly connecting with the process output of the manufacturing end, the selection results can directly guide production, which greatly shortens the conversion cycle from selection to manufacturing.

[0197] It is understood that the above scenarios are merely examples and do not constitute a limitation on the application scenarios of the technical solutions provided in the embodiments of this application. The technical solutions of this application can also be applied to other scenarios. For example, as those skilled in the art will know, with the evolution of system architecture and the emergence of new business scenarios, the technical solutions provided in the embodiments of this application are also applicable to similar technical problems.

[0198] The sequence numbers of the embodiments in this application are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0199] The steps in the method of this application embodiment can be adjusted, combined, or deleted according to actual needs.

[0200] The units in the device of this application embodiment can be merged, divided, and deleted according to actual needs.

[0201] In this application, the same or similar terms, concepts, technical solutions and / or application scenario descriptions are generally described in detail only when they appear for the first time. When they appear again, they are generally not repeated for the sake of brevity. When understanding the technical solutions and other contents of this application, the same or similar terms, concepts, technical solutions and / or application scenario descriptions that are not described in detail later can be referred to their previous relevant detailed descriptions.

[0202] In this application, the descriptions of the various embodiments have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0203] The technical features of the present application can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of the present application.

[0204] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A motion cable selection system, characterized in that, The system includes: The data acquisition layer is used to acquire the operating condition parameters input by the user terminal, and to obtain the damage reference values ​​corresponding to the operating condition parameters from the damage accumulation model. The decision engine is used to perform multi-level matching based on the operating condition parameters and the damage reference value to determine the cable selection scheme corresponding to the operating condition parameters; The solution output layer is used to output the cable selection solution and output the manufacturing process parameters corresponding to the cable selection solution to the manufacturing end.

2. The system according to claim 1, characterized in that, The data acquisition layer includes: The parameter parsing module is used to convert the operating condition parameters input by the user into structured parameters; The data interface module is used to read selection rule data from the knowledge base and to read the damage reference value corresponding to the structured parameter from the damage accumulation model.

3. The system according to claim 2, characterized in that, The decision engine includes: The flexibility level determination module is used to determine the flexibility level of the cable based on the structured parameters and the damage reference value; A material matching module is used to match the material and structure of the cable according to the structured parameters and the flexibility level; The compliance matching module is used to match the corresponding product certification standards based on the certification requirements in the structured parameters.

4. The system according to any one of claims 1 to 3, characterized in that, The output layer of the scheme includes: The user-end output module is used to output the cable selection scheme, which includes at least one of the following: flexibility level, model and specifications, material of each layer, electrical parameters, certification information and expected cycle life. The manufacturing output module is used to output the manufacturing process parameters, which include at least one of the following: bill of materials, process flow, and process parameters.

5. The system according to any one of claims 1 to 3, characterized in that, The system also includes: The feedback layer is used to obtain the manufacturing results corresponding to the cable selection scheme and update the knowledge base and / or damage accumulation model based on the results.

6. A method for selecting motion cables, characterized in that, The method includes: Obtain the operating condition parameters input by the user; Obtain the damage reference value corresponding to the operating condition parameter from the damage accumulation model; Based on the operating parameters and the damage reference values, a multi-level matching process is performed to determine the cable selection scheme. Output the cable selection scheme and output the manufacturing process parameters corresponding to the cable selection scheme to the manufacturing end.

7. The method according to claim 6, characterized in that, The acquisition of operating condition parameters input by the user terminal includes: Convert the operating condition parameters in natural language format, structured form format, or historical model format into unified structured parameters.

8. The method according to claim 7, characterized in that, The multi-level matching includes: The flexibility level is determined based on the structured parameters and the damage reference values; The material and structure are matched according to the structuring parameters and the flexibility level; Match product certification standards to the certification requirements in the structured parameters.

9. The method according to any one of claims 6 to 8, characterized in that, The determination of the cable selection scheme includes: Output user-side selection solutions and manufacturing-side process solutions; The user terminal selection scheme includes at least one of the following: flexibility level, model specifications, material of each layer, electrical parameters, certification information, and expected cycle life; The manufacturing process plan includes at least one of a bill of materials, a process flow, and process parameters.

10. The method according to any one of claims 6 to 8, characterized in that, The method further includes: Obtain the manufacturing results corresponding to the cable selection scheme and / or the usage results of the cable corresponding to the cable selection scheme; Update at least one of the knowledge base and / or the damage accumulation model based on the manufacturing results and / or the usage results.

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