Tension dynamic compensation control method and system of inductance winding equipment and storage medium

Abstract

The present application relates to the tension control technical field of inductance winding equipment, and discloses a tension dynamic compensation control method and system of inductance winding equipment and a storage medium.Synchronously acquire the winding spindle angle position, wire outlet position, wire feeding metering increment, tension buffer mechanism position change and tension detection value, determine the winding wire increment, buffer wire length and unclosed wire length difference, and identify the tension transmission effective state or tension transmission limited state in combination with the wire wrapping state; when transmission is effective, the tension deviation update feedback compensation amount is allowed, when transmission is limited, the feedback compensation amount is locked and the to-be-released wire length difference is accumulated; after transmission recovery, the release section is selected according to the subsequent winding path, wire arrangement reversing position and buffer remaining stroke, and the to-be-released wire length difference is verified by using the actual wire length balance result.The present application makes the tension feedback participate in compensation in the state of being able to represent the force state of the winding contact point, reduces the repeated compensation and tension mutation caused by the change of buffer absorption or guiding transmission.

Description

Technical Field

[0001] This invention relates to the field of motion control and conductor tension control technology for inductor winding equipment, and particularly to a method, system, and storage medium for dynamic tension compensation control of inductor winding equipment. Background Technology

[0002] Inductors are typically manufactured by winding enameled wire, covered conductor, or other wires onto an inductor frame, magnetic core, or coil support using a winding machine. During winding, the winding spindle rotates the inductor, a wire guide mechanism moves along the inductor's axial direction or a predetermined trajectory, and a wire feeding mechanism, braking mechanism, or tension adjustment mechanism assists in supplying the conductor. The conductor tension affects the winding's fit, interlayer arrangement, insulation stress, and subsequent forming quality. Therefore, winding machines are usually equipped with tension detection and tension buffer mechanisms, and adjust the wire feeding speed or braking force based on the detected tension deviation.

[0003] Existing tension control methods typically use the tension value output by the tension detection mechanism directly as the basis for closed-loop control, or add feedforward compensation based on the spindle speed, wire diameter, or pre-set process section when the spindle accelerates or decelerates, wire reversal occurs, or the winding profile changes. While these methods can handle tension changes already occurring near the tension detection point, in the inductor winding path, tension levers, floating guide wheels, fixed guide wheels, guide holes, or wire guide nozzles are usually also present between the tension detection point and the actual contact point between the wire and the inductor. The wire forms a transmission path of a certain length and wrapping relationship between these components, and the displacement change generated at the wire feeding end is not necessarily immediately and equally transmitted to the winding contact point.

[0004] When the cable guide mechanism moves, the winding contact point crosses a contour corner, or the spindle's operating state changes, the required amount of cable at the winding end changes in adjacent control cycles. The short-term difference between the cable supply and the required amount can initially be absorbed by the positional change of the tension buffer mechanism, keeping the tension detection value within the allowable range, while the available stroke of the tension buffer mechanism continuously decreases. Simultaneously, when the wrap angle and sliding state of the conductor on the guide member change, the tension transmission relationship on both sides of the guide member also changes, and the tension detection value may temporarily fail to reflect the actual force at the winding contact point. Continuing to compensate for the tension deviation by accumulating feedback at this time easily leads to treating the detection results during the buffer absorption or limited transmission period as new cable supply mismatches.

[0005] After the conductor slips again, the wrap angle decreases, or the tension buffer mechanism returns to its original position, the previously untransmitted conductor length may be released all at once. If the controller does not save the historical conductor length relationship and only provides feedback on the tension change after the recovery, it may repeatedly compensate for the same conductor length mismatch, causing the conductor feeding actuator to reverse its movement, the tension buffer mechanism to touch its travel boundary, or a sudden change in winding tension. Simply increasing the tension sampling frequency, increasing the feedback gain, or setting a tension alarm threshold cannot solve the problem that the tension detection value is not representative of the feedback under certain operating conditions.

[0006] Therefore, a control scheme is needed that can simultaneously consider the actual wire feeding, the wire required for winding, the absorption or release of wire length by the tension buffer mechanism, and the wire transmission state, so that the tension detection value can only participate in feedback updates when it can reflect the force on the winding contact point, and the wire length difference formed during the transmission restriction period can be continuously and controlled in the subsequent winding process. Summary of the Invention

[0007] The purpose of this invention is to provide a dynamic tension compensation control method, system, and storage medium for inductor winding equipment, in order to solve the problems that tension feedback may drive incorrect compensation and historical line length differences may be repeatedly compensated when there is a change in the buffer absorption and transmission state between the tension detection point and the winding contact point.

[0008] To achieve the above objectives, the present invention provides a dynamic tension compensation control method for an inductor winding device. The method simultaneously acquires the angular position of the winding spindle, the conductor exit position of the wire guide mechanism, the wire feeding metering increment, the position change of the tension buffer mechanism, and the tension detection value. Based on the effective winding profile of the inductor, the winding layer position, the angular position, and the conductor exit position, the required winding increment for the current control cycle is determined. Furthermore, based on the position change, the buffer wire length absorbed or released by the tension buffer mechanism in the current control cycle is determined.

[0009] The method determines the unclosed wire length difference based on the balance relationship between the wire delivery metering increment, the winding wire requirement increment, and the buffer wire length. It also determines the current control cycle as either an effective tension transmission state or a restricted tension transmission state based on the correspondence between the wire wrapping state on the guide member, the unclosed wire length difference, the position change, and the tension detection value.

[0010] In the state of effective tension transmission, the feedback compensation amount is updated based on the deviation between the detected tension value and the target tension, and the wire feeding mechanism or braking actuator is controlled based on the increase in required winding length and the feedback compensation amount. In the state of restricted tension transmission, the feedback compensation amount is locked, and the wire feeding mechanism or braking actuator is controlled based on the increase in required winding length and the centering requirement of the tension buffer mechanism, and the unclosed wire length difference is accumulated as the wire length difference to be released.

[0011] When the tension transmission restricted state changes to the tension transmission effective state, a release section is selected based on the changing direction of the increase in the required winding length in the subsequent winding path, the reversal position of the winding, and the remaining stroke of the tension buffer mechanism. Within the release section, the release correction amount used to reduce the difference in the length of the line to be released is added to the control amount corresponding to the increase in the required winding length, and the difference in the length of the line to be released is cancelled based on the newly determined difference in the length of the unclosed line.

[0012] In one implementation, the current effective winding profile is determined based on the basic winding profile of the inductor frame or magnetic core, the conductor diameter, and the completed winding layers; the predicted winding contact points of the conductor at the start and end of the current control cycle are determined based on the conductor exit position, the rotation direction of the winding spindle, and the current effective winding profile; the profile advance length along the winding direction between the two predicted winding contact points is determined, and the length change of the free conductor segment from the conductor exit to the predicted winding contact point within the current control cycle is determined; the sum of the profile advance length and the length change is determined as the required winding increment.

[0013] In one embodiment, the wire feeding metering increment is determined by the output of a metering encoder corresponding to the metering wheel in contact with the conductor. The tension buffer mechanism includes a movable guide wheel capable of changing the conductor path length. The buffer wire length is determined based on the position change distance of the movable guide wheel and the number of conductor segments whose length changes along with the movable guide wheel. The wire feeding increment on the pay-off drive side is determined based on the rotation amount of the pay-off drive encoder and the current pay-off reel diameter. When the difference between the wire feeding increment on the pay-off drive side and the wire feeding metering increment has the same direction over multiple consecutive control cycles, the wire feeding metering increment is used in determining the unclosed wire length difference, and updating the pay-off reel diameter using the output of the pay-off drive encoder is paused.

[0014] In one embodiment, the expected movement direction of the tension buffer mechanism and the expected change direction of the tension detection value are determined based on the direction of the unclosed line length difference. When the tension buffer mechanism absorbs the unclosed line length difference according to the expected movement direction, and the tension detection value does not change according to the expected change direction, or when the unclosed line length difference continuously accumulates during the increase of the wrap angle of the guide member, the tension transmission is determined to be in a restricted state. When the tension detection value changes according to the expected change direction, the unclosed line length difference begins to decrease, and the tension buffer mechanism no longer absorbs the buffer line length in the same direction, the tension transmission is determined to be in an effective state.

[0015] In one embodiment, under the tension transmission restricted state, the feedback compensation amount before entering the tension transmission restricted state is maintained, and the accumulation of the deviation between the tension detection value and the target tension is stopped; a centering correction amount is generated according to the wire feeding direction required to move the tension buffer mechanism to the middle of its stroke, and when the centering correction amount does not increase the difference in the length of the wire to be released, the centering correction amount is superimposed on the control amount corresponding to the increase in the required winding length; when the centering correction amount will increase the difference in the length of the wire to be released, the centering correction amount is limited, and the rotational speed of the winding spindle is reduced until the remaining stroke of the tension buffer mechanism meets the buffer wire length required for subsequent changes in the required winding length.

[0016] In one implementation, the wire feeding correction direction required to reduce the wire length difference to be released is determined based on the direction of the wire length difference to be released; from the winding spindle angular position segment after the start of the tension transmission effective state, a continuous angular position segment is selected that does not include the reversing position of the wire guide mechanism and the current effective winding profile corner position, and the natural change direction of the required winding wire increment is consistent with the wire feeding correction direction; based on the expected winding wire increment for each control cycle within the continuous angular position segment, the remaining stroke of the tension buffer mechanism, and the allowable tension change range, the allocation value of the release correction amount within the continuous angular position segment is determined; after each control cycle, the wire length difference to be released is re-determined based on the actual wire feeding metering increment, the actual buffer wire length, and the actual winding wire increment, instead of directly deducting the wire length difference to be released based on the already issued release correction amount.

[0017] In one implementation, during the release of the unreleased line length difference, if any of the following occurs: the direction of change of the tension detection value is opposite to the expected direction of tension change corresponding to the wire feeding correction direction; the tension buffer mechanism enters a preset boundary stroke; or the wire guiding mechanism reverses direction prematurely, the output of the release correction amount is stopped, and the unresolved unreleased line length difference is carried over to the subsequent release section. When the winding layer position changes, the effective winding profile and the required winding increment are re-determined based on the changed winding layer position. The unresolved unreleased line length difference is retained, and the feedback compensation amount of the previous winding layer position is stopped until the tension transmission effective state is re-entered at the changed winding layer position.

[0018] This invention also provides a tension dynamic compensation control system for an inductor winding device, including a controller and a winding spindle encoder, a wire feeding position feedback interface, a wire feeding metering unit, a tension buffer mechanism position detection unit, a tension detection unit, and an execution control interface, all connected to the controller. The controller forms an unclosed wire length difference based on the wire feeding metering increment minus the required winding wire determined by the winding motion state and the buffer wire length determined by the position change of the tension buffer mechanism. It then determines the tension transmission state based on the correspondence between the unclosed wire length difference, the wire wrapping state, the position change, and the tension detection value. The controller sets a feedback admission control path controlled by the tension transmission state and a wire length release control path connected to the feedback admission control path.

[0019] The feedback admission control path allows the tension detection value to update the feedback compensation amount when tension transmission is effective, and prevents the tension detection value from updating the feedback compensation amount when tension transmission is restricted, and transfers the unclosed line length difference to the line length difference to be released. After the tension transmission restricted state changes to the tension transmission effective state, the line length release control path selects the release segment according to the changing direction of the subsequent winding required wire increment, the wire reversal position, and the remaining stroke of the tension buffer mechanism, and outputs a control amount to the active wire feed driver, brake actuator, or tension regulating actuator through the execution control interface to verify the line length difference to be released.

[0020] In one embodiment, the tension buffer mechanism is a tension swing arm, a floating guide wheel mechanism, or a movable guide wheel mechanism capable of changing the length of at least two conductor paths; the wire feeding metering unit includes a metering wheel in contact with the conductor and a metering encoder for detecting the rotation of the metering wheel; the controller adds a period identifier to each detection output according to the same motion control cycle, so that the wire feeding metering increment, the required winding wire increment, the buffer wire length, and the tension detection value within the same cycle jointly participate in the determination of the unclosed wire length difference and the tension transmission state.

[0021] The present invention also provides a computer-readable storage medium having a computer program stored thereon, wherein when the computer program is executed by a processor in a controller of an inductor winding device, the processor causes the processor to implement the above-described tension dynamic compensation control method for the inductor winding device.

[0022] Compared with the prior art, the present invention uses the relationship between the actual wire feeding, winding consumption and the absorption or release of the buffer mechanism as the control basis, so that the tension detection value is judged for transmission effectiveness before entering the feedback adjustment, which can reduce the erroneous feedback caused by the buffer mechanism temporarily absorbing the wire length difference or the change of the guiding transmission state.

[0023] During periods of restricted tension transmission, this invention locks the feedback compensation amount and continuously saves the unclosed line length difference as the line length difference to be released, preventing the same historical line length difference from being re-identified as a new tension disturbance after tension detection recovers. The line length difference to be released is then used to define the release section, release direction, and release amount, thus forming a continuous closed loop around the same physical state with feedback admission control and line length release control.

[0024] This invention arranges the release process according to the direction of the required wire change in the subsequent winding path, the wire reversal position, and the remaining stroke of the tension buffer mechanism. It also re-verifies the difference in the length of the wire to be released based on the actual wire delivery measurement result, the actual buffer wire length, and the actual increase in the required wire for winding. This can reduce erroneous verification caused by the execution command not being actually completed, the metering wheel slipping, or the release section ending prematurely.

[0025] Furthermore, when centering correction may increase the difference in length of the line to be released or the remaining buffer stroke is insufficient, limiting centering correction and reducing the winding spindle speed preserves the tension buffer mechanism's ability to continue absorbing path changes, thereby creating a mutually constrained operating relationship between tension control, buffer stroke management, and winding motion control. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments are briefly described below. The drawings are used to illustrate the technical relationships of the present invention and do not constitute a limitation on the specific shape, installation proportions, or deployment positions of the components.

[0027] Figure 1 This is a schematic diagram of the overall flow of the tension dynamic compensation control method for inductor winding equipment provided in an embodiment of the present invention;

[0028] Figure 2 This is a schematic diagram illustrating the relationship between the wire transmission path, detection location, and execution object provided in an embodiment of the present invention;

[0029] Figure 3 This is a schematic diagram illustrating the process for determining the required winding wire increment, buffer wire length, and unclosed wire length difference in an embodiment of the present invention.

[0030] Figure 4 This is a schematic diagram of the tension transmission state determination and feedback admission control logic provided in an embodiment of the present invention;

[0031] Figure 5 This is a schematic diagram of the release section selection and verification process for the difference in length to be released provided in an embodiment of the present invention;

[0032] Figure 6 This is a schematic diagram illustrating the composition and information control relationship of the tension dynamic compensation control system provided in an embodiment of the present invention. Detailed Implementation

[0033] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings and embodiments. The described embodiments are used to explain the present invention, not to limit the scope of protection of the present invention. Equivalent substitutions made by those skilled in the art to the detection interface, actuator form, or controller deployment method without changing the core technical relationship of the present invention can all be used to implement the present invention.

[0034] This invention relates to the process of continuously winding conductors using an inductor winding device. The inductor can be an inductor frame with a winding area, a magnetic rod, a toroidal core, a slotted core, or other components capable of carrying a coil. The winding device includes at least a winding spindle, a wire guiding mechanism, a wire feeding path, a tension buffer mechanism, a tension detection mechanism, and an actuator capable of changing the wire feeding state. The winding spindle drives the inductor to rotate relative to the conductor; the wire guiding mechanism changes the position of the conductor outlet relative to the inductor; the actuator can be an active wire feeding motor, a wire release brake, a servo tensioner, or a combination of at least two of these.

[0035] like Figure 2 As shown, the conductor, after passing through the wire feeding metering unit, tension buffer mechanism, tension detection unit, and at least one guiding component from the wire feeding end, enters the winding contact point of the inductor from the conductor outlet of the wire guiding mechanism. The tension buffer mechanism changes the conductor path length by moving the guide wheel to absorb the instantaneous difference in wire length between the feeding end and the winding end. The tension detection unit can be arranged after or before the tension buffer mechanism, and the correspondence between the detection value and the subsequent conductor path is established through equipment calibration. The guiding component includes a fixed guide wheel, guide hole, ceramic eye, conductor tube, or wire guide nozzle, and its function is to define the spatial path of the conductor.

[0036] There is a spatial gap between the tension detection unit and the actual winding contact point. The conductor may pass through one or more guide members within this spatial gap, and the movement of the cable guiding mechanism will change the conductor's entry direction, exit direction, contact point, and wrap angle relative to the guide members. Therefore, this invention does not presuppose that any tension detection value can represent the force at the winding contact point, but rather uses the conductor's wrapping state on the guide members, the actual line length balance, and the tension response together as the basis for whether tension feedback is acceptable.

[0037] The controller uses the motion control cycle as the common processing unit for all signals. The motion control cycle can be determined by the winding spindle servo control cycle, the device's programmable logic controller (PLC) scan cycle, or an independent real-time task cycle. The outputs of the winding spindle encoder, wire feeding position feedback interface, wire feeding metering unit, tension buffer mechanism position detection unit, and tension detection unit are all appended with corresponding sampling times or cycle identifiers. When different interfaces cannot complete sampling at the same time, the controller aligns the signals according to adjacent sampled values ​​and spindle angular positions, ensuring that each increment entering the same control cycle corresponds to the same actual winding process.

[0038] For signals output at different sampling frequencies, the controller first selects valid samples according to the start and end times of the current motion control cycle. Position signals form position changes based on the valid positions corresponding to the cycle start and end points; wire delivery metering signals form wire delivery metering increments based on the cumulative count difference within the cycle; tension detection signals form initial and final representative values ​​from valid samples near the cycle start and end points, and the difference between these values ​​determines the tension change direction for the current cycle. When the tension sampling frequency is higher than the motion control frequency, each representative value can be determined by removing outliers from multiple valid samples near the corresponding boundary; if only a single-sided representative value is obtained, the tension change direction is not determined based on this. If the timestamp of any necessary signal exceeds the maximum allowable lag time for the current cycle, or if the cycle start or end data required to form the increment is missing, the current cycle is determined as an incomplete information cycle, no new unclosed line length difference is formed, and the feedback compensation and pending release line length difference are not updated. During a single period of incomplete information, the controller maintains the confirmed state and safety control output from the previous period. If the winding spindle angle position or wiring position is missing, or if the incomplete information exceeds the allowable holding period, the controller decelerates and stops under control according to the abnormal handling procedure. The maximum lag time and allowable holding period are determined based on the sampling period of the corresponding signal, the motion control period, and the equipment stop response time, ensuring that the same spindle angle position segment is not counted repeatedly or omitted.

[0039] like Figure 1As shown, the tension dynamic compensation control method provided in this embodiment includes steps S101 to S105. Step S101: Simultaneously acquire the winding motion state, actual wire feeding state, buffer mechanism state, and tension detection state, and determine the required wire increment and buffer wire length for the current control cycle. Step S102: Determine the unclosed wire length difference based on the actual wire feeding increment, required winding wire increment, and buffer wire length, and determine the tension transmission state. Step S103: Allow the tension deviation to update the feedback compensation amount when tension transmission is effective. Step S104: Lock the feedback compensation amount when tension transmission is restricted, and accumulate the wire length difference to be released. Step S105: After tension transmission recovers, select the release section, and verify the wire length difference to be released through the actual wire length balance result.

[0040] Before executing step S101, the controller reads the process data for the current winding task. The process data includes at least the basic winding profile of the inductor, conductor diameter, target tension, winding direction, wiring trajectory, target number of turns, and winding layer position. The basic winding profile represents the winding bearing surface before the current winding layer thickness is added, and can be provided by product design data, a sequence of profile points formed by equipment teaching, or a profile template pre-established according to the product type. The process data is only used to describe the current inductor and winding process and does not require setting a specific equipment model.

[0041] The current effective winding profile represents the outer contour that the conductor can contact at the current winding layer. For inductor frames or cores with relatively regular contours, the controller can shift the basic winding profile outward based on the number of completed winding layers and the conductor diameter. For inductors with slot walls, corners, or local transition surfaces, the basic winding profile can be discretized into contour points arranged according to the winding direction, and a new sequence of contour points can be formed based on the outward normal of each contour point and the current layer thickness. In cases where the wiring pitch causes incomplete local overlap between adjacent conductors, the effective profile can be locally corrected based on the current wiring position. The purpose of these processes is to obtain conductor contact boundaries that correspond to the current winding layer, rather than limiting the use of a single geometric shift algorithm.

[0042] The controller determines the predicted winding contact point based on the conductor exit position, the winding spindle angle position, the winding spindle rotation direction, and the current effective winding profile. For convex or segmented convex profiles, the position tangent to or first in contact with the current effective winding profile can be determined from the conductor exit along the conductor entry direction. For profiles with slots or partial obstructions, the first contact position can be determined along the actual reachable path of the conductor from the exit to the inductor. For equipment with fixed product profiles and wiring trajectories, a lookup relationship between the spindle angle position, wiring position, and predicted winding contact point can be established in advance. All determination methods should ensure that the predicted winding contact point is continuously updated with the spindle and wiring movement or updated sequentially according to the profile segments. When contact segment switching occurs at the edge of the slot or at a discontinuous profile position, the actual reachable adjacent contact points before and after the switching are used to determine the profile advance length for the corresponding control cycle, avoiding including unreachable profile segments in the required winding increment.

[0043] like Figure 3 As shown, after determining the predicted winding contact points at the start and end times of the current control cycle, the controller calculates the profile advance length between the two predicted winding contact points along the current winding direction. The profile advance length represents the length of the conductor newly covering the surface of the inductor during the current control cycle. Simultaneously, the controller determines the length of the free conductor segment from the conductor outlet to the predicted winding contact point at each of the two times, and subtracts the length of the free conductor segment at the start of the cycle from the length of the free conductor segment at the end of the cycle to obtain the change in the length of the free conductor segment. The sum of the profile advance length and the change in the length of the free conductor segment constitutes the winding requirement increment for the current control cycle.

[0044] The change in the length of the free conductor segment can be positive or negative. The length of the free conductor segment increases when the wire guide mechanism moves away from the predicted winding contact point or when the conductor exit moves outward relative to the contour; conversely, the length decreases when the wire guide mechanism moves closer to the predicted winding contact point or when the conductor exit moves inward relative to the contour. The controller incorporates the change in the length of the free conductor segment into the incremental increase in winding demand, ensuring that the wire delivery reference not only follows the contour loss caused by the spindle rotation but also the spatial path length changes with the wire laying motion.

[0045] The wire feeding metering increment represents the actual length of conductor delivered through the wire feeding metering position and into the winding path within the current control cycle. In a preferred embodiment, the wire feeding metering unit includes a metering wheel and a metering encoder that are in direct contact with the conductor. The controller determines the wire feeding metering increment by multiplying the ratio of the pulse increment of the metering encoder within the current control cycle to the effective count per revolution of the metering encoder by the calibrated effective circumference of the metering wheel. When the encoder interface directly outputs the rotation angle or cumulative length, the conversion relationship between the rotation angle and the effective circumference or the difference between the cumulative length at the start and end of the cycle is used, respectively. The effective circumference of the metering wheel can be obtained through fixed-length wire feeding calibration after equipment assembly. The effective count per revolution of the metering encoder is determined according to the encoder resolution and the actual counting method used by the controller. The calibration result is used to compensate for the thickness of the rubber coating on the metering wheel, the contact compression state, and manufacturing deviations.

[0046] The pay-off drive encoder reflects the rotation of the pay-off motor or pay-off reel. The controller converts this rotation into a pay-off drive-side wire feeding increment based on the current pay-off reel diameter, and uses this increment for drive status verification or reel diameter update. When the difference between the pay-off drive-side wire feeding increment and the wire feeding measurement increment measured by the metering wheel remains in the same direction for multiple consecutive control cycles, it indicates that at least one of the following—reel diameter estimation, drive connection, or metering path—is inconsistent with the current actual state. In this case, the controller uses the wire feeding measurement increment in direct contact with the conductor in the calculation of the unclosed wire length difference and suspends updating the pay-off reel diameter using the output of the pay-off drive encoder to prevent the incorrect reel diameter from further altering the wire feeding conversion relationship.

[0047] Pausing the roll diameter update does not equate to stopping the pay-off drive. The controller can still generate pay-off control quantities based on the required wire increment, feedback compensation, and actuator limits; however, it will not use the current pay-off drive encoder output as the basis for roll diameter learning. Once the difference between the wire feed increment and the wire metering increment on the pay-off drive side returns to a non-continuous oscillation, and the wire metering wheel is in normal contact, the controller can restart the roll diameter update. If the metering wheel detects a loss of pressure, stops rotating, or loses contact with the wire, the controller will not use the metering results to update the wire length status and will reduce the spindle speed or stop it under control according to the abnormal handling procedure.

[0048] The positional change of the tension buffer mechanism is obtained by a rocker arm angle sensor, a linear displacement sensor, or a moving guide wheel position encoder. The controller determines the buffer line length based on the positional change of the moving guide wheel within the current control cycle and the actual wire threading path. For structures where the moving guide wheel simultaneously changes the length of multiple wire paths, the buffer line length is the algebraic sum of the length differences between the changed segments at the end of the cycle and at the beginning of the cycle; only when each changed segment is parallel to the direction of movement and the direction of length change is the same can it be converted by multiplying the movement distance by the number of wire segments that change together. When the trajectory of the moving guide wheel is not parallel to the direction of the wire segments, the length change is calculated based on the assembly geometry of the endpoints of each segment, or a mapping between the movement position and the buffer line length is established through fixed-length movement calibration. Thus, the buffer line length reflects the actual change in the length of the wire path, rather than simply replacing the change in the wire path with the displacement of the guide wheel.

[0049] This implementation specifies that: when the tension buffer mechanism increases the internal wire storage path, the buffer wire length is positive; when the tension buffer mechanism releases the wire from the radial winding end of the internal wire storage path, the buffer wire length is negative. The symbols are only used to illustrate the wire length relationship; the actual control program can store the direction indicator and absolute length separately. The buffer wire length reflects the actual wire length absorbed or released by the tension buffer mechanism in the current control cycle, not the absolute position of the tension buffer mechanism. The absolute position of the tension buffer mechanism is also used to determine the middle of the stroke, the remaining stroke, and the boundary stroke.

[0050] The controller determines the unclosed wire length difference based on the wire delivery metering increment, the required winding wire increment, and the buffer wire length. Before performing wire length balancing, the three data points are converted to the same length unit and confirmed to correspond to the same motion control cycle. Specifically, the required winding wire increment is first subtracted from the wire delivery metering increment, and then the buffer wire length already absorbed by the tension buffer mechanism is subtracted. The result represents the portion of the length of the wire path that has not yet been consumed by the winding end or absorbed by the tension buffer mechanism. If the result is positive, it indicates that there is excess wire length that has not yet been closed; if the result is negative, it indicates that the wire length required for the current winding consumption and buffer changes has not yet been replenished by the wire delivery end. If the tension buffer mechanism releases the wire, the buffer wire length is negative, and the released length participates in the wire length balancing of the current cycle.

[0051] To ensure continuous continuity of line length states across different control cycles, the controller employs a unified line length direction: both the incremental metering of the wire delivery and the incremental wire required for winding are positively represented by the length of the conductor moving from the delivery end to the winding end; the buffer line length is positively represented by increasing the storage path and negatively represented by releasing the conductor from the storage path. The unclosed line length difference for the current control cycle is determined using the following formula:

[0052] ,

[0053] in, Indicates the current control cycle. This represents the difference in the length of the unclosed line during the current control cycle. This indicates the incremental metering of the feed line during the current control cycle. This indicates the increase in the required winding length for the current control cycle. This represents the buffer line length for the current control cycle. All increments in the formula use the same unit of length.

[0054] After entering the tension transmission restricted state, when the length difference of the unclosed conductor in the current cycle is in the same direction as the length difference of the conductor to be released in the previous cycle, the absolute length of the length difference of the conductor to be released increases; when they are in opposite directions, the absolute length of the length difference of the unclosed conductor in the current cycle is first reduced by the absolute length of the length difference of the conductor to be released in the previous cycle. Only when the absolute length of the reverse length difference in the current cycle exceeds the length difference of the conductor to be released in the previous cycle does the length difference of the conductor to be released change direction. Thus, the length of the same conductor segment remains continuously assigned before and after the state switch, and is not repeatedly accumulated due to the sign change.

[0055] The unclosed wire length difference may be affected by encoder quantization, conductor elastic deformation, and signal synchronization errors within a single control cycle. The controller can determine the wire length resolution interval based on the incremental fluctuations obtained during the no-load operation and stable winding phases of the equipment, and treat small results falling within the resolution interval but lacking a continuous direction as zero values. The resolution interval is used to eliminate measurement noise and is not used as a single judgment threshold for the tension transmission state. When the unclosed wire length difference maintains the same direction in multiple consecutive control cycles, the controller retains its continuous change relationship.

[0056] The wrapping state of the conductor on the guide member includes the guide member currently in contact with the conductor, the direction of the conductor entering and leaving the guide member, the wrap angle formed by the conductor and the guide member, and the direction of change of the wrap angle. For fixed guide wheels and cable guide nozzles, the controller can determine the wrapping state based on the equipment assembly position, the conductor exit position, and the predicted winding contact point; for guide holes or ceramic eyelets, the equivalent wrapping state can be represented by the deflection relationship between the conductor's entry and exit directions. The wrapping state does not require precise calculation of the friction coefficient; its function is to identify whether the current conductor path is in a geometric stage where transmission stagnation is more likely to occur.

[0057] During the equipment initialization phase, the controller establishes a correspondence between the direction of the unclosed wire length difference and the expected movement direction of the tension buffer mechanism and the expected change direction of the tension detection value. The installation direction of the mechanism can be used to determine the expected movement direction of the buffer mechanism; the expected change direction of the tension detection value is first confirmed through low-speed wire feeding calibration. During calibration, under the condition that the tension transmission is stable and the tension buffer mechanism is located in the central area, fine adjustments to increase and decrease wire feeding are applied within the safe range of the equipment, and the corresponding directions of the unclosed wire length difference, the movement direction of the buffer mechanism, and the change direction of the tension detection value are recorded. For structures where the detection point is located after the buffer mechanism and the residual overfeed makes the detection path tend to be relaxed, the overfeed state can correspond to the direction of tension decrease; for structures with different detection point positions, wire paths, or tension actuator arrangements, a uniform tension change direction is not preset, but the calibration result is used. The correspondence is saved according to the detection point position, wire path, and actuator control direction, and is recalibrated after the wire path or sensor installation position is changed.

[0058] like Figure 4 As shown, the controller determines the feedback admission state based on the corresponding changes. When the tension buffer mechanism absorbs the current unclosed line length difference according to the expected direction of movement, but the tension detection value does not change accordingly according to the expected direction of change, it indicates that the line length change mainly stops before the buffer section or guide member, and the tension detection value is insufficient to represent the force at the winding contact point. The controller determines this as a tension transmission restricted state. When the unclosed line length difference accumulates continuously during the increase of the guide member's wrap angle, it is also determined to be a tension transmission restricted state, because the continuous increase of the wrap angle and the continuous accumulation of the line length difference in the same direction indicate that the retention of the transmission path by the displacement change is increasing.

[0059] The determination of the tension transmission limitation state is achieved through continuous confirmation rather than triggering a single sampling point. The number of control cycles required for continuous confirmation is determined based on the tension detection noise, the mechanical response of the buffer mechanism, and the spindle operating speed, ensuring that the confirmation time covers at least one identifiable buffer position change without crossing major cable reversing sections. The unclosed cable length difference used as the basis for continuous confirmation should be outside the cable length resolution range, and the position change of the buffer mechanism should be greater than its position detection resolution. If the buffer position change, tension detection change, and wrapping state give conflicting judgment results, the controller will temporarily not enable feedback compensation updates and will continue to save the unclosed cable length state according to the cable length balance result; if the input signal is temporarily missing or the data under the same cycle identifier is incomplete, the tension transmission state confirmed in the previous cycle will be used, and learning updates to the feedback compensation amount and the cable length difference to be released will be prohibited.

[0060] When the tension detection value changes in the expected direction, the unclosed line length difference begins to decrease, and the tension buffer mechanism no longer absorbs the buffer line length in the same direction, it indicates that the line length change formed at the wire feeding end has been transmitted to the tension detection position and the winding path, and the controller determines it to be in an effective tension transmission state. To avoid frequent state switching near the boundary, the effective tension transmission state is also continuously confirmed. If the tension transmission is restricted and transitions to an effective tension transmission state, and the line length difference to be released is not zero, the controller enters the line length release sub-state under the effective tension transmission state: the tension detection value can participate in the feedback compensation update, but the update magnitude of the feedback compensation amount and the release correction amount are both constrained by the allowable tension change range, the change rate of the actuator, and the remaining stroke of the tension buffer mechanism; after the line length difference to be released is cleared, the controller exits the line length release sub-state and resumes the normal feedback compensation update upper limit.

[0061] Under effective tension transmission conditions, the deviation between the detected tension value and the target tension enters the feedback control path. The feedback control path can employ proportional-integral control, incremental control with output limits, or equivalent feedback control based on the existing tension regulator in the equipment. The output of the feedback control is a feedback compensation quantity, used to correct the basic wire feeding control quantity calculated from the incremental wire required for winding. Before combination, the basic wire feeding control quantity and each correction quantity are converted to the same execution control domain: for position-type active wire feeding drives, the equivalent wire feeding length for each control cycle is used as the control quantity; for speed-type active wire feeding drives, the equivalent wire feeding length is converted to wire feeding speed according to the control cycle; for brake actuators or servo tensioners, the equivalent wire length correction is converted into braking torque, braking current, adjustment displacement, or torque control quantity based on the historical response during low-speed calibration or the effective tension transmission phase. The feedback compensation quantity, release correction quantity, and centering correction quantity are first determined in the equivalent wire length domain and then mapped to the control quantity of the selected actuator, avoiding direct addition of length, speed, torque, and current. The tension detection value, target tension, and allowable tension variation range all use the same force unit.

[0062] The update rate and output limit of the feedback compensation are jointly determined by the actuator's responsiveness, the allowable range of tension variation, and the remaining stroke of the tension buffer mechanism. When the tension buffer mechanism approaches the stroke boundary, even if the tension transmission is effective, the controller restricts the feedback compensation direction from allowing the buffer mechanism to continue approaching the same boundary. This restriction does not change the feedback admission decision logic, but rather prevents feedback adjustment from consuming the remaining stroke of the buffer mechanism used to absorb subsequent path changes.

[0063] In the long-release sub-state, the controller generates a feedback compensation increment caused by tension deviation and a release correction amount caused by the difference in length of the line to be released. When both cause the line control quantity to change in the same direction, the output can be combined within the allowable rate of change of the actuator, the allowable tension change range, and the remaining buffer stroke. When the two are in opposite directions, the controller retains the feedback compensation portion necessary to prevent the tension detection value from exceeding the allowable tension change range and temporarily suspends the remaining feedback increment that would directly offset the release correction. If the tension detection value has reached the boundary of the allowable tension change range, the release correction stops and the feedback compensation takes priority in maintaining tension safety. Thus, tension feedback can participate in control after effective transmission, but it will not hide historical line length differences that have not yet been verified back in the feedback compensation amount.

[0064] Upon entering the tension transmission restricted state, the controller maintains the feedback compensation amount from before entering this state and stops accumulating the deviation between the detected tension value and the target tension. Maintaining the feedback compensation amount prevents the actuator from undergoing abrupt changes due to a single state switch; stopping the accumulation of deviation prevents distorted tension from forming a continuously increasing compensation in the controller. At this time, the wire feeding control still operates according to the current winding wire demand increment to maintain the basic wire feeding relationship corresponding to the spindle and wire laying movements.

[0065] The unclosed length difference formed under tension transmission constraints is accumulated over the control cycle as the unreleased length difference. During accumulation, the direction of the length difference is retained: unclosed length differences in the same direction increase the unreleased length difference, while unclosed length differences in the opposite direction that can be offset by actual length balance decrease the unreleased length difference. If length differences in different directions alternate but are all within the measurement resolution range, the controller does not repeatedly change the direction of the unreleased length difference. Therefore, the unreleased length difference represents the historical length state that has not been closed between the feed end, buffer section, and winding end during the transmission constraint period.

[0066] The centering requirement of the tension buffer mechanism is determined based on its absolute position relative to the midpoint of its stroke. The midpoint of the stroke is not a single point; it can be configured as a central interval that simultaneously retains available stroke in both the wire storage and wire release directions. The controller determines the corresponding wire feeding direction and generates a centering correction amount based on the direction of motion required to return the moving guide wheel to the central interval. The rate of change of the centering correction amount is limited by the allowable tension variation range and the actuator's response capability to prevent the centering action of the buffer mechanism itself from creating new tension shocks.

[0067] The travel midpoint and preset boundary travel are determined based on the mechanically movable range of the tension buffer mechanism. During equipment initialization or maintenance calibration, the controller reads the positions of the two mechanical ends and reserves a safety travel within each end position; this safety travel at least covers the buffer position changes that may occur during the period from receiving a deceleration or stop command to the completion of the winding spindle's response. The area between the two safety travels is the permissible operating range, and the area within the permissible operating range that simultaneously reserves travel in both the wire storage and release directions is the central range. The safety travel is recalibrated after changes to the equipment structure, the spindle's maximum operating speed, or the braking response.

[0068] Before outputting the centering correction amount, the controller determines whether the correction amount will increase the length difference of the line to be released. For example, when there is an over-delivered length difference of the line to be released, a centering correction that reduces subsequent line delivery and moves the buffer mechanism towards the center will not increase the length difference of the line to be released and can be added to the basic line delivery control amount; if the buffer mechanism requires additional line delivery for centering, and adding more line delivery will further amplify the over-delivered state, then the centering correction amount is limited. For cases where the length difference of the line to be released is in the direction of missing line, the same judgment is performed in the opposite direction.

[0069] When centering correction is limited, the controller predicts the required wire length change from the current spindle angular position to the next wire reversal position or the next contour corner position, and, in conjunction with the actuator's response time, determines the maximum dynamic buffer wire length that the tension buffer mechanism needs to temporarily handle within that response time. This maximum dynamic buffer wire length is not the total geometric wire length change in the angular position segment, but rather the maximum cumulative difference between the required wire length change during the period before the basic wire feeding actuator completes its follow-up and the actual wire feeding change. If the available buffer wire length calculated from the current remaining stroke of the tension buffer mechanism is insufficient to handle the maximum dynamic buffer wire length, the controller reduces the spindle speed, thereby reducing the required wire length change and follow-up requirements within the actuator's response time. After the spindle speed decreases, the controller continues to check the available buffer wire length; if the available buffer wire length is still insufficient or the buffer mechanism enters the mechanical boundary, the equipment execution is controlled to stop.

[0070] When the tension transmission state changes from restricted to active, the controller does not immediately convert the entire difference in the length to be released into a single execution quantity, but instead initiates the length release control path. For example... Figure 5 As shown, the line length release control path first determines the line feeding correction direction based on the direction of the line length difference to be released. When the line length difference to be released indicates an over-feeding length, the line feeding correction direction is to reduce the line feeding relative to the basic line feeding amount; when the line length difference to be released indicates that the required line is not replenished, the line feeding correction direction is to increase the line feeding relative to the basic line feeding amount.

[0071] The controller predicts the incremental changes in winding demand for multiple subsequent spindle angular position segments based on the current effective winding profile, spindle rotation direction, and wiring trajectory. The reversing position of the wiring guide mechanism is determined by the position where the speed in the wiring trajectory drops to zero and the direction of motion changes in subsequent cycles. When the current effective winding profile is represented by discrete profile segments, the controller compares the tangential direction of adjacent profile segments with the corresponding free conductor length change direction; when the tangential direction change of adjacent profile segments exceeds the direction change range corresponding to the profile discrete error, or when the free conductor length change direction changes, the corresponding position is determined as the profile turning angle position. Based on the winding spindle speed and actuator response time, the controller sets exclusion angle position segments before and after the reversing position and the profile turning angle position, respectively. The exclusion segment covers the spindle angle traversed by the actuator to complete one direction adjustment. The exclusion angle position segment is not used as a release segment to avoid simultaneous rapid changes in the basic winding demand and conductor transmission state.

[0072] After excluding reversing and turning positions, the controller selects continuous angular position segments where the natural direction of the incremental wire demand during winding aligns with the direction of wire feed correction. The natural direction of change refers to the increasing or decreasing trend of the basic wire feed control quantity between adjacent control cycles, not the positive or negative direction of the incremental wire demand itself. For example, when the required wire length difference needs to be released and a reduction in wire feed is required, segments where the basic wire feed control quantity naturally decreases with the winding path are prioritized, allowing the release correction to be superimposed along the original deceleration direction of the actuator; conversely, when the required wire length difference needs to be released and a growth in wire feed is required, segments where the basic wire feed control quantity naturally increases are prioritized, allowing the release correction to be superimposed along the original acceleration direction of the actuator. This reduces reverse switching and response lag in the actuator.

[0073] The allocatable release correction amount for each candidate continuous angular position segment is determined according to the upper limit of each cycle and uniformly converted into the equivalent line length within the current control cycle before comparison. The controller determines the following respectively: the absolute length of the line length difference to be released that has not yet been verified; the path correction capacity that maintains the original increasing or decreasing trend of the basic line feeding control amount after the release correction is superimposed; the available buffer line length converted from the current position of the tension buffer mechanism to the corresponding boundary travel; the allowable equivalent line length converted from the tension margin corresponding to the boundary of the allowable tension change range from the current tension detection value; and the executable equivalent line length converted from the control change amount that the line feeding mechanism or braking actuator can actually complete within one control cycle. The path correction capacity is determined by trial calculation of the candidate segments cycle by cycle, and the position where the direction of the basic line feeding control amount reverses after the release correction is superimposed is taken as the capacity boundary. The permissible tension variation range is provided by the process data of the current conductor and winding stage, or calibrated based on the target tension and the equipment's permissible fluctuation range during the stable winding stage. The correspondence between tension margin and equivalent wire length is calibrated separately for increasing and decreasing wire feeding directions using low-speed wire feeding, or determined based on the local response during the effective tension transmission stage. The actuator capability is mapped to the actual achievable equivalent wire length according to the aforementioned execution control domain. The controller uses the minimum value not exceeding the aforementioned equivalent wire length limits as the release correction amount for the current cycle, which can be evenly distributed within the candidate segment or segmented according to the natural variation amplitude of the basic wire feeding control amount.

[0074] After the release correction amount is superimposed on the control amount corresponding to the increase in required winding length, the wire feeding mechanism or braking actuator performs the correction. The controller does not directly reduce the difference in length to be released based on the already issued release correction amount, because the execution command may be affected by speed limits, braking torque limits, wire feeding reel inertia, or metering wheel slippage. After each control cycle, the controller re-acquires the actual wire feeding metering increment, actual buffered wire length, and actual increase in required winding length, and redetermines the unclosed length difference of the current cycle according to the unified length direction. When the wire length release sub-state remains effective, the changes in tension detection value and buffer mechanism position are consistent with the current release direction, and the current cycle has not entered the wire reversal or contour corner exclusion section, if the direction of the unclosed length difference of the current cycle is opposite to that of the length difference to be released, the length difference to be released is cancelled according to the smaller of their absolute lengths; when the two directions are the same, the unclosed length difference continues to increase the length difference to be released. If the reverse unclosed line length difference exceeds the unresolved line length difference to be released, the original unresolved line length difference is first resolved to zero, and the excess portion is treated as the new line length state for the current cycle and used in subsequent tension transfer judgments. If the above response consistency conditions are not met simultaneously, the historical unresolved line length difference is not used to resolve the reverse unclosed line length difference; instead, the current release correction is stopped, and the unclosed line length difference is treated as the new line length state to avoid erroneous resolution caused by disturbances from other paths.

[0075] During the release process, the controller simultaneously checks the direction of tension detection value change, the position of the tension buffer mechanism, and the status of the cable guide mechanism. When the direction of tension detection value change is opposite to the expected direction of tension change that should be generated by the current cable feeding correction, it indicates that the conductor transmission status, metering relationship, or winding path is inconsistent with the release plan, and the controller stops the current release correction. When the tension buffer mechanism enters the preset boundary stroke, the release stops to retain a mechanical safety margin. When the cable guide mechanism reverses direction prematurely due to process adjustments or motion errors, the current continuous angular position segment no longer meets the release conditions, and the output of the release correction amount also stops.

[0076] After the release stops, the controller retains the remaining length difference to be released that has not yet been balanced and offset by the actual length, and then searches for subsequent release sections that meet the conditions. The length difference to be released will not be cleared due to a release interruption, nor will it be deleted if the tension detection value briefly returns to normal. The controller only ends the current length release process when the length difference to be released enters the length resolution range, the tension buffer mechanism returns to the allowable operating range, and the tension transmission state remains effective.

[0077] When the winding layer changes, the relationship between the conductor contact profile and the free conductor segment changes. The controller redetermines the current effective winding profile based on the changed winding layer, conductor diameter, and basic winding profile, and recalculates the required winding increment. Unresolved unreleased length differences represent the actual length relationship and are therefore retained across layers. The feedback compensation amount from the previous winding layer is related to the effective profile and transmission conditions of the previous layer and cannot be directly used. The controller stops using the feedback compensation amount until the effective tension transmission state is reconfirmed at the changed winding layer.

[0078] The following section uses a continuous winding process to illustrate the sequential relationship between each step. After winding begins, the controller reads the basic winding profile and the first winding layer of the current inductor, and receives signals from the spindle, wire laying, wire feeding metering, buffer position, and tension detection. The controller first determines the predicted winding contact point and the required wire increment, and then forms the unclosed wire length difference based on the relationship between actual wire feeding, winding consumption, and buffer absorption. When the wire laying guide mechanism approaches the profile transition position, the buffer mechanism moves towards the wire storage direction, but the tension detection value does not show a change corresponding to the over-feeding state. The unclosed wire length difference continues to accumulate in the same direction during the increase of the wrap angle, and the controller enters the tension transmission restricted state accordingly.

[0079] After entering the tension transmission restricted state, the controller maintains the previous feedback compensation amount, does not continue to accumulate tension deviation, and adds the line length difference that was not completed in each cycle to the line length difference to be released. If the position of the buffer mechanism deviates from the center range, the controller checks whether the centering correction will increase the line length difference to be released; if it can simultaneously center back and reduce the line length difference, it performs centering back; if the two conflict, it prioritizes limiting the increase of the line length difference and reduces the spindle speed according to the remaining buffer stroke.

[0080] After the cable guide mechanism passes the transition position, the conductor wrap angle begins to decrease, the tension detection value changes in the expected direction, the unclosed cable length difference begins to converge, and the buffer mechanism no longer moves towards the cable storage direction. The controller, after continuous confirmation, enters the cable length release sub-state under effective tension transmission conditions, and selects from subsequent angular position segments a segment where the basic cable delivery amount naturally changes along the required correction direction, and does not include cable reversal or contour angles. Release correction is output in segments according to the required cable amount of the candidate segment and the remaining buffer travel, while the tension detection value simultaneously participates in feedback compensation within the controlled update upper limit. Each cycle verifies the cable length difference to be released based on the actual cable delivery result of the metering wheel and the actual buffer displacement; after the historical cable length relationship is closed, the controller exits the cable length release sub-state and resumes the regular feedback compensation update upper limit.

[0081] In the aforementioned continuous process, the tension transmission status is not an alarm label for equipment failure, but directly changes whether the tension deviation can enter the feedback controller; the length difference to be released is not merely a historical field for recording, but a control status that determines the subsequent direction of wire feeding correction, release section, release amount, and process exit conditions. Together, these two ensure that the primary wire length mismatch remains consistent from its generation, temporary storage, transmission recovery, to actual write-off.

[0082] like Figure 6 As shown, this embodiment further provides a tension dynamic compensation control system for an inductor winding device. The system includes a controller, a winding spindle encoder, a wire placement position feedback interface, a wire feeding metering unit, a tension buffer mechanism position detection unit, a tension detection unit, and an execution control interface. The winding spindle encoder outputs the spindle angular position and rotational speed to the controller; the wire placement position feedback interface outputs the wire outlet position and wire movement direction to the controller; the wire feeding metering unit outputs the wire feeding metering increment to the controller; the tension buffer mechanism position detection unit outputs the change in the position of the moving guide wheel or the change in the angle of the swing arm; the tension detection unit outputs the tension detection value; and the execution control interface connects to an active wire feeding driver, a braking actuator, or a tension regulating actuator.

[0083] The controller stores the basic winding profile, winding process data, guide component installation position, and signal direction calibration relationship. Based on the spindle angle position, conductor exit position, and winding layer position, the controller determines the required winding increment. It determines the buffer wire length based on changes in the position of the moving guide wheel or the angle of the rocker arm, and calculates the unclosed wire length difference by subtracting the required winding increment and the buffer wire length from the wire feed metering increment. The conductor wrapping state can be determined in real-time by the controller based on the guide component installation position, conductor exit position, and predicted winding contact point, or it can be provided by a pre-established table corresponding to the spindle angle position and wire routing position.

[0084] The feedback admission control path in the controller receives unclosed wire length difference, conductor wrapping status, tension buffer mechanism position changes, and tension detection values, and outputs a feedback admission status that allows or prevents updates. The feedback admission status directly controls whether the tension deviation enters the feedback compensation calculation, rather than merely controlling the display or alarm. When tension transmission is restricted, the feedback admission control path also sends the unclosed wire length difference to a pending release wire length difference state and provides the activation conditions for the wire length release control path.

[0085] The line length release control path receives the line length difference to be released, the incremental change in subsequent winding, the reversing position of the winding, the contour corner position, and the remaining buffer stroke, forming a release segment and a release correction amount. The execution control interface combines control quantities according to the tension transmission state: when tension transmission is effective and the line length difference to be released is within the line length resolution range, it outputs the basic wire feeding control quantity, the feedback compensation quantity, and the centering correction quantity that does not conflict with the line length state; when tension transmission is limited, it outputs the basic wire feeding control quantity, the locked feedback compensation quantity, and the centering correction quantity that does not increase the line length difference to be released, and does not output the release correction quantity; in the line length release sub-state, it combines the basic wire feeding control quantity, the feedback compensation quantity, the release correction quantity, and the centering correction quantity according to the aforementioned direction conflict handling results. Each control quantity first completes direction judgment and limit allocation in the equivalent line length domain, and then maps it to the control domain of the active wire feeding driver, the braking actuator, or the tension regulating actuator respectively; the control outputs of different physical quantities are not directly added together. The mapped combined control quantity is uniformly limited by the actuator change rate, tension allowable range, and buffer boundary, and then output by the execution control interface. When different actuators exist simultaneously, the controller can allocate low-frequency line length changes to the active wire release drive and rapid tension changes to the tension regulating actuator, but the feedback admission and the line length difference verification to be released still follow the same line length closed loop.

[0086] The tension buffer mechanism can be a tension swing arm, a floating guide wheel mechanism, or a moving guide wheel mechanism capable of changing the length of at least two conductor paths. For a tension swing arm, the position detection unit detects the swing arm angle and calculates the position of the moving guide wheel based on the swing arm's geometry; for a linear floating guide wheel, the position detection unit directly detects the linear displacement of the guide wheel; for a multi-segment conductor path structure, the controller determines the buffer line length based on the actual number of conductor segments involved in the change and the direction of each conductor segment. The above mechanism configurations do not alter the technical relationship of using the actual buffer line length for line length balancing.

[0087] The wire feeding metering unit is preferably positioned in a location that does not change with the wire unwinding diameter and can maintain stable contact with the conductor. It includes a metering wheel and a metering encoder. The metering wheel can be driven by conductor friction or maintained in contact by a light pressure wheel. The controller adds the same motion control cycle identifier to the outputs of the winding spindle encoder, the wire laying position feedback interface, the metering encoder, the tension buffer mechanism position detection unit, and the tension detection unit. Thus, the system uses the wire feeding metering increment, the required winding wire increment, the buffer wire length, and the tension detection value within the same cycle to determine the wire length difference and transmission status.

[0088] The controller can be a motion controller for the winding equipment, a programmable controller, a real-time control unit in an industrial computer, or a control combination formed by a servo driver and a host controller. The feedback admission control path and the line length release control path can be executed by the same processor, or by different processing units while maintaining the cycle identifier and state transfer relationship. Changes in the executing entity or deployment location do not affect the control relationship of the unclosed line length difference on the feedback admission or the constraint relationship of the line length difference to be released on the subsequent release process.

[0089] In an alternative implementation, the device does not have a separate metering wheel, but the pay-off shaft encoder, roll diameter detection unit, and conductor anti-slip detection unit can jointly provide a calibrated wire feed metering increment. In this case, the wire feed metering unit can be implemented by the interface combination. This alternative still requires that the wire feed metering increment be independent of the simple pay-off command and that it be able to stop using erroneous roll diameter updates when the roll diameter estimation is abnormal.

[0090] In another alternative implementation, the wrapping state of the guide member is not obtained through real-time geometric calculations. Instead, during the equipment teaching phase, the wire entry direction, exit direction, and wrapping angle change segments are recorded according to the spindle angle position and the wiring position. During the winding operation, the corresponding state is read based on the position of the current cycle. For equipment with fixed product models and repetitive winding paths, this method can reduce the amount of real-time calculations while maintaining the correspondence between the wrapping state and the current winding stage.

[0091] When the target tension changes with the winding layer or process stage, the controller updates the target tension and feedback compensation output limits before entering a new target tension stage. However, the unclosed line length difference and the line length difference to be released are still continuously stored according to the actual line length relationship. If the target tension switch and the winding layer switch occur simultaneously, the feedback compensation update is only opened after the effective state of tension transmission is reconfirmed at the new layer, so as to avoid mixing the detection deviation caused by the change in target value with the historical line length difference.

[0092] For signal anomalies, the controller handles them according to information integrity and mechanical safety boundaries. When the spindle angular position or cable position is missing, the required cable increment cannot be reliably determined, the controller stops releasing correction and executes deceleration or controlled stop; when the metering wheel signal is missing, the actual cable feed amount is not fabricated based on the drive command; when the buffer position detection is abnormal, compensation that may consume the remaining stroke is not continued; when the tension detection is abnormal, the feedback access path remains closed, but cable length balancing can still be used to maintain basic cable feed and safe shutdown.

[0093] The present invention also provides a computer-readable storage medium, which can be disposed in a winding equipment controller, an industrial computer, or a program storage unit that can communicate with the controller. When the computer program stored in the storage medium is executed by a processor, it completes signal period alignment, determination of effective winding profile, calculation of required winding increment, conversion of buffer wire length, determination of unclosed wire length difference, judgment of tension transmission status, feedback access control, accumulation of wire length difference to be released, selection of release section, and actual verification.

[0094] The computer program can be divided into signal synchronization tasks, winding path tasks, wire length balancing tasks, feedback access tasks, and wire length release tasks according to their functional tasks. Data is transmitted between tasks through the same motion control cycle identifier, unclosed wire length difference, tension transmission status, and wire length difference to be released. Task names, the number of software threads, or storage locations can be changed, but the wire feeding metering increment, winding wire requirement increment, and buffer wire length for each cycle cannot be separated, nor can the feedback compensation amount be updated using distorted tension under tension transmission constraints.

[0095] The above embodiments illustrate the core technical relationships of the present invention. In practical applications, the contour shape of the inductor, the conductor material, the form of the wire feeding mechanism, the structure of the tension buffer mechanism, and the deployment method of the controller can be determined according to the equipment conditions. As long as the actual wire feeding, the required winding wire, and the buffer wire length form an unclosed wire length difference, the tension feedback access is controlled using the unclosed wire length difference and the wire wrapping state, and the unreleased wire length difference is verified and cancelled according to the controlled winding path after the transmission is restored, the technical solution of the present invention can be implemented.

Claims

1. A method for dynamic tension compensation control of an inductor winding device, characterized in that, include: The angular position of the winding spindle, the conductor exit position of the wire guide mechanism, the wire feeding metering increment, the position change of the tension buffer mechanism, and the tension detection value are acquired simultaneously. Based on the effective winding profile of the inductor, the winding layer, the angular position, and the conductor exit position, the required winding increment for the current control cycle is determined. Based on the position change, the buffer wire length absorbed or released by the tension buffer mechanism in the current control cycle is determined. The unclosed wire length difference is determined based on the wire delivery metering increment, the winding wire requirement increment, and the buffer wire length. The current control cycle is determined to be either a tension transmission effective state or a tension transmission limited state based on the relationship between the wire wrapping state on the guide member, the unclosed wire length difference, the position change, and the tension detection value. Under the effective tension transmission state, the feedback compensation amount is updated according to the deviation between the tension detection value and the target tension, and the wire feeding mechanism or braking actuator is controlled according to the wire demand increment and the feedback compensation amount. Under the condition of restricted tension transmission, the feedback compensation amount is locked, and the wire feeding mechanism or the braking actuator is controlled according to the increase in the required winding length and the return-to-center requirement of the tension buffer mechanism. The unclosed wire length difference is accumulated as the wire length difference to be released. When the tension transmission restricted state changes to the tension transmission effective state, a release section is selected based on the changing direction of the increase in the required winding length in the subsequent winding path, the reversal position of the winding, and the remaining stroke of the tension buffer mechanism. Within the release section, the release correction amount used to reduce the difference in the length of the line to be released is added to the control amount corresponding to the increase in the required winding length, and the difference in the length of the line to be released is cancelled based on the newly determined difference in the length of the unclosed line.

2. The tension dynamic compensation control method for inductor winding equipment according to claim 1, characterized in that, The determination of the winding requirement increment for the current control cycle includes: The current effective winding profile is determined based on the basic winding profile of the inductor frame or magnetic core, the wire diameter, and the completed winding layers. The predicted winding contact points of the conductor at the start and end times of the current control cycle are determined based on the conductor exit position, the rotation direction of the winding spindle, and the current effective winding profile. Determine the profile advance length along the winding direction between two predicted winding contact points, and determine the length change of the free conductor segment from the conductor outlet to the predicted winding contact point within the current control cycle; The sum of the advance length of the contour and the change in length is determined as the required wire increment for the winding.

3. The tension dynamic compensation control method for inductor winding equipment according to claim 1, characterized in that, Both the wire feeding metering increment and the winding wire requirement increment are positively defined by the length of the conductor moving from the feeding end to the winding end. The buffer wire length is positively defined by the increase in the internal wire storage path of the tension buffer mechanism and negatively defined by the release of the conductor from the radial winding end of the internal storage line. The difference in unclosed wire length is determined by the following formula: ， in, Indicates the current control cycle. This represents the difference in the length of the unclosed line during the current control cycle. This indicates the incremental metering of the feed line during the current control cycle. This indicates the increase in the required winding length for the current control cycle. The buffer line length represents the current control cycle. The unclosed line length difference, wire feeding metering increment, winding wire requirement increment, and buffer line length all use the same length unit. The wire feeding metering increment is determined by the output of the metering encoder corresponding to the metering wheel in contact with the conductor; the tension buffering mechanism includes a movable guide wheel that can change the length of the conductor path, and the buffer line length is determined according to the position change distance of the movable guide wheel and the number of conductor segments whose length changes together with the movable guide wheel; The wire feed increment on the wire drive side is determined based on the rotation amount of the wire feed drive encoder and the current wire roll diameter. When the difference between the wire feed increment on the wire drive side and the wire feed metering increment has the same direction in multiple consecutive control cycles, the wire feed metering increment is used to determine the unclosed wire length difference, and the update of the wire roll diameter using the output of the wire feed drive encoder is paused.

4. The tension dynamic compensation control method for inductor winding equipment according to claim 1, characterized in that, Determining the effective state or limited state of tension transmission includes: The expected movement direction of the tension buffer mechanism and the expected change direction of the tension detection value are determined based on the direction of the length difference of the unclosed line. When the tension buffer mechanism absorbs the unclosed line length difference in the expected direction of movement, and the tension detection value does not change in the expected direction of change, or when the unclosed line length difference accumulates continuously during the increase of the wrap angle of the guide member, the tension transmission is determined to be in a restricted state. When the tension detection value changes in the expected direction, the difference in length of the unclosed line begins to decrease, and the tension buffer mechanism no longer absorbs the buffer line length in the same direction, the tension transmission is determined to be in an effective state.

5. The tension dynamic compensation control method for inductor winding equipment according to claim 1, characterized in that, In the state of restricted tension transmission, maintain the feedback compensation amount before entering the state of restricted tension transmission, and stop accumulating the deviation between the tension detection value and the target tension; A centering correction amount is generated based on the wire feeding direction required to move the tension buffer mechanism to the middle of the stroke. When the centering correction amount does not increase the difference in the length of the wire to be released, the centering correction amount is added to the control amount corresponding to the increase in the required winding length. When the centering correction amount increases the difference in the length of the line to be released, the centering correction amount is limited, and the rotational speed of the winding spindle is reduced until the remaining stroke of the tension buffer mechanism meets the buffer line length required for subsequent changes in the winding length.

6. The tension dynamic compensation control method for inductor winding equipment according to claim 1, characterized in that, The selected release segment includes: Determine the wire feeding correction direction required to reduce the length difference of the line to be released based on the direction of the length difference of the line to be released. From the winding spindle angular position segment after the start of the effective tension transmission state, select a continuous angular position segment that does not include the reversal position of the wire guide mechanism and the current effective winding profile corner position, and where the natural change direction of the required wire increment is consistent with the wire feeding correction direction. Based on the expected increase in the required winding length for each control cycle within the continuous angular position segment, the remaining stroke of the tension buffer mechanism, and the allowable tension variation range, the distribution value of the release correction amount within the continuous angular position segment is determined. After each control cycle ends, the difference in length to be released is re-determined based on the actual wire delivery metering increment, the actual buffer wire length, and the actual winding wire requirement increment, instead of directly deducting the difference in length to be released based on the already issued release correction amount.

7. The tension dynamic compensation control method for inductor winding equipment according to claim 6, characterized in that, During the process of releasing the line length difference to be released, if any of the following situations occur: the direction of change of the tension detection value is opposite to the expected direction of tension change corresponding to the wire feeding correction direction, the tension buffer mechanism enters the preset boundary stroke, or the wire guide mechanism changes direction in advance, the output of the release correction amount is stopped, and the line length difference to be released that has not yet been cleared is carried over to the subsequent release section. When the winding layer position changes, the effective winding profile and the required winding length increment are re-determined based on the changed winding layer position. The unresolved length difference to be released is retained, and the feedback compensation amount of the winding layer position before the change is stopped, until the tension transmission effective state is re-entered at the changed winding layer position.

8. A tension dynamic compensation control system for an inductor winding device, comprising a controller and a winding spindle encoder, a wire feeding position feedback interface, a wire feeding metering unit, a tension buffer mechanism position detection unit, a tension detection unit, and an execution control interface respectively connected to the controller, characterized in that: The controller receives the winding motion state through the winding spindle encoder and the cable position feedback interface, receives the cable feeding metering increment through the cable feeding metering unit, receives the position change of the tension buffer mechanism through the tension buffer mechanism position detection unit, and receives the tension detection value through the tension detection unit. It determines the buffer cable length based on the position change and forms the unclosed cable length difference by subtracting the cable demand increment determined by the winding motion state and the buffer cable length from the cable feeding metering increment. The controller determines the tension transmission state based on the correspondence between the unclosed line length difference, the wire wrapping state, the position change, and the tension detection value, and includes a feedback admission control path controlled by the tension transmission state. The feedback admission control path allows the tension detection value to update the feedback compensation amount when the tension transmission is effective, and prevents the tension detection value from updating the feedback compensation amount when the tension transmission is restricted, and transfers the unclosed line length difference to the line length difference to be released. The controller also includes a line length release control path connected to the feedback admission control path. After the tension transmission restricted state changes to the tension transmission effective state, the line length release control path selects the release section according to the changing direction of the subsequent winding required wire increment, the wire reversal position and the remaining stroke of the tension buffer mechanism, and outputs a control quantity to the active wire feed driver, brake actuator or tension adjustment actuator through the execution control interface to verify the line length difference to be released.

9. The tension dynamic compensation control system for the inductor winding equipment according to claim 8, characterized in that, The tension buffer mechanism is a tension swing arm, a floating guide wheel mechanism, or a moving guide wheel mechanism capable of changing the length of at least two conductor paths. The wire feeding metering unit includes a metering wheel that contacts the wire and a metering encoder for detecting the rotation amount of the metering wheel. The controller adds a periodic identifier to the outputs of the winding spindle encoder, the cable position feedback interface, the metering encoder, the tension buffer mechanism position detection unit, and the tension detection unit according to the same motion control cycle, so that the cable feeding metering increment, the required cable increment, the buffer cable length, and the tension detection value within the same cycle jointly participate in the determination of the unclosed cable length difference and the tension transmission state.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor in the controller of the inductor winding device, the processor performs the tension dynamic compensation control method of the inductor winding device according to any one of claims 1 to 7.

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