Full-automatic threading intelligent control method and system for building decoration electrical wires

Abstract

The application discloses a building decoration electrical wire full-automatic threading intelligent control method and system, belongs to the technical field of wire full-automatic threading control, and comprises the following steps: obtaining a threading target length of a building decoration pre-buried wire pipe, generating a stop front pushing instruction and a follow-up release instruction when a control window end condition is met or a driving load reaches an upper limit of the driving load, determining an unrecoverable pipe entering amount of the current round, and identifying a current round wire feeding result as an effective pushing state, an entrance side abnormal state or a pipe internal pressure lag state and performing targeted control. The application solves the technical problems of the prior art, such as false threading footage in a concealed wire pipe, entrance side abnormality and pipe internal pressure lag misjudgment, low damage intervention timeliness and wire insulation layer easy abrasion, by judging threading progress according to the motion amount of an active wire feeding mechanism or a single driving load threshold value, and being difficult to distinguish between a theoretical wire feeding length, an actual pipe entering length and a real effective pipe entering length after rebound release.

Description

Technical Field

[0001] This invention relates to the field of fully automatic wire threading control technology, and in particular to a fully automatic intelligent control method and system for wire threading in building decoration. Background Technology

[0002] During electrical installation in building renovations, it is typically necessary to thread wires for lighting, sockets, low-voltage circuits, or equipment power supply into conduits embedded in walls, floors, or ceilings. Since conduits are usually concealed after installation, workers cannot directly observe the wire's position and resistance level within the conduit. Furthermore, the conduit path often includes bends, joints, localized diameter variations, burrs at the pipe ends, construction deviations, and dust and mortar residue. During threading, the wires are affected by conduit wall friction, bend resistance, and the combined resistance of multiple wires pressing against each other. Traditional manual threading methods rely on wires, traction ropes, or manual pushing, which can lead to difficulties in threading long distances, multiple bends, or conduits with significant resistance, resulting in repeated pulling, low threading efficiency, and wear on the wire insulation.

[0003] To improve construction efficiency, electric wire threading equipment or automatic wire threading machines have emerged. These devices typically apply pushing force to the conductor through a drive wheel, clamping wheel, traction wheel, or gear transmission mechanism, and can control the conductor's movement into the conduit based on the drive wheel's rotation, the drive motor's operating status, or a preset wire feeding length. Some devices also include speed regulation, reversing, counting, remote control, or overload protection functions to achieve automatic conductor feeding and abnormal shutdown. However, this type of control usually directly uses the movement of the drive feeding mechanism as the basis for threading progress, or only determines a jammed state when the motor current or torque reaches a threshold. It focuses more on whether the conductor can continue to be pulled, and is less likely to accurately reflect the true and effective advancement status of the conductor within the concealed conduit.

[0004] Especially in pre-embedded conduits for building decoration, the theoretical wire feeding length of the active wire feeding mechanism, the actual wire insertion length at the conduit inlet, and the actual advancement of the wire end within the conduit are not always consistent. When the wire passes through bends, misaligned joints, or local diameter changes, the drive wheel may continue to rotate, and a small increase in wire insertion may be detected at the inlet side. However, this increase may simply be the result of elastic compression, local stagnation, or slight slippage of the wire within the conduit, and does not represent a stable forward advancement of the wire end. If existing equipment still judges the wire threading progress based on the theoretical wire feeding length of the drive wheel, it is easy to generate false progress, leading to problems such as prematurely judging proximity to the exit, misjudging the completion of the task, or continuing to push too hard.

[0005] Furthermore, the transition from normal wire feeding to complete jamming is usually not instantaneous, but rather involves a gradual decrease in the actual wire feed increment, a decline in wire feeding effectiveness, and a gradual increase in drive load. Existing control methods, which only implement shutdown, retraction, or alarm processing after the wire has completely stopped, the drive motor has stalled, or the load exceeds a threshold, often miss the opportunity for low-damage intervention. At this point, the wire may already be experiencing significant axial compression and high-friction contact at bends or local diameter changes. Continuing to feed the wire or repeatedly retracting it can easily cause scratches on the wire insulation, bends at the ends, repeated wear at the same location, and may even lead to subsequent retraction failures or require manual modification. Summary of the Invention

[0006] To address the technical problems of existing technologies that rely on the movement of an active wire feeding mechanism or a single drive load threshold to determine wire threading progress, making it difficult to distinguish between the theoretical wire feeding length, the actual insertion length, and the true effective insertion length after springback release, leading to false advances in concealed conduits, misjudgments of inlet-side anomalies and conduit pressure stagnation, untimely intervention for low-damage situations, and easy wear of conductor insulation, a fully automated intelligent control method and system for wire threading in building decoration is provided. The technical solution is as follows: On the one hand, a fully automated intelligent control method for wiring electrical conductors in building decoration is provided, which includes: Obtain the target length of the wiring in the pre-embedded conduit for building decoration, and during the process of pushing the electrical wire to be threaded into the pre-embedded conduit, obtain the theoretical wire delivery amount, the actual wire insertion amount, and the driving load in this round according to the control window.

[0007] When the control window end condition is met or the drive load reaches the drive load limit, a stop push command and a follow-up release command are generated, so that the conductor can move back slightly towards the inlet due to the compression and release inside the tube, and the rebound amount of the current round of stopping formed by the slight rebound is obtained.

[0008] The irrecoverable infeed volume for this round is determined based on the actual infeed volume and the rebound volume during the stop-feeding phase. Based on the correspondence between the irrecoverable infeed volume and the theoretical wire delivery volume for this round, as well as the changes in the driving load, the wire delivery result for this round is identified as an effective propulsion state, an abnormal state on the inlet side, or a stagnation state inside the pipe.

[0009] When the system is identified as being in a valid advance state, the amount of unrecoverable cable entry in this round is included in the cumulative valid cable entry length, and a continue cable delivery command or a stop delivery command is generated based on the cumulative valid cable entry length and the target cable length.

[0010] When an abnormal state is identified at the inlet side, the theoretical wire delivery volume, actual wire entry volume, and irrecoverable wire entry volume of this round are not included in the cumulative effective wire entry length, and a conductor displacement detection retest command and a wire delivery clamp retest command are generated.

[0011] When the pipe is identified as being under pressure, the irreversible amount of wire fed into the pipe in this round is not included in the cumulative effective length of wire fed into the pipe. The wire is stopped from being pushed forward based on the theoretical amount of wire fed into the pipe in this round, and a reverse unloading command for the wire and a pressure position record are generated.

[0012] On the other hand, it provides a fully automated intelligent control system for wiring electrical wires in building decoration, including: The data acquisition module is used to obtain the target length of the wires to be threaded into the pre-embedded conduit in building decoration, and to obtain the theoretical wire delivery amount, the actual wire insertion amount and the driving load in this round according to the control window during the process of pushing the electrical wires to be threaded into the pre-embedded conduit.

[0013] The stop-and-feed springback analysis module is used to generate stop-and-push commands and follow-up release commands when the control window end conditions are met or the drive load reaches the upper limit of the drive load. This allows the conductor to move back slightly towards the inlet due to the compression and release inside the tube, and to obtain the stop-and-feed springback amount formed by the slight back movement in this round.

[0014] The wire delivery result identification module is used to determine the unrecoverable wire delivery volume in this round based on the actual wire delivery volume and the rebound volume during the current round of delivery stoppage. Based on the correspondence between the unrecoverable wire delivery volume and the theoretical wire delivery volume in this round, as well as the change in driving load, the module identifies the wire delivery result in this round as an effective propulsion state, an abnormal state on the inlet side, or a stagnation state inside the pipe.

[0015] The effective advancement execution module is used to include the current unrecoverable pipe insertion quantity in the cumulative effective pipe insertion length when the effective advancement state is identified, and to generate a continue delivery command or a stop delivery command based on the cumulative effective pipe insertion length and the target threading length.

[0016] The entry anomaly execution module is used to exclude the theoretical wire delivery volume, actual wire entry volume, and irrecoverable wire entry volume of the current round from the cumulative effective wire entry length when an entry anomaly is identified. It also generates a conductor displacement detection retest command and a wire delivery clamp retest command.

[0017] The in-pipe pressure hysteresis execution module is used to prevent the irrecoverable in-pipe flow from being included in the cumulative effective in-pipe flow length when the in-pipe pressure hysteresis state is identified. It stops pushing the conductor forward based on the theoretical wire delivery amount of the current round and generates a conductor reverse unloading command and pressure position record.

[0018] The beneficial effects of the technical solutions provided by the embodiments of the present invention include at least the following: 1. This invention synchronously acquires the theoretical wire feeding amount, actual wire insertion amount, and driving load of the current cycle through the control window, and acquires the rebound amount of the current cycle before and after stopping the push, thereby determining the irrecoverable insertion amount of the current cycle. Combining the correspondence between the irrecoverable insertion amount and the theoretical wire feeding amount of the current cycle, as well as changes in the driving load, it identifies the effective advancement state, the abnormal state at the inlet side, or the stagnation state within the tube. Therefore, the wire threading control process no longer relies solely on the rotation of the active wire feeding mechanism to determine the threading progress. It can eliminate false advances caused by wire elastic compression, inlet side slippage, and rebound after stopping the push, making the cumulative effective insertion length closer to the true advance where the wire is stably retained within the tube. Simultaneously, it can perform retest verification or reverse unloading for inlet side abnormalities and stagnation within the tube, reducing wire insulation wear caused by erroneous pushes, misjudgments of placement, and ineffective repeated retractions.

[0019] 2. After the control window end condition is met or the drive load reaches the drive load limit, a stop push command and a follow-up release command are generated. The reverse displacement increment is continuously acquired, and the rebound amount of this round is determined based on the rebound stabilization time, rebound stabilization threshold, and maximum rebound observation time. Then, the irrecoverable in-pipe amount of this round is obtained by subtracting the rebound amount of this round from the actual in-pipe amount. This can deduct the inlet direction return caused by the compression and release inside the pipe after the wire feeding is stopped from the actual in-pipe amount, avoiding the misinterpretation of the elastic compression of the conductor at bends, joints, or local diameter changes as the effective in-pipe length. This reduces the risk of prematurely judging the approach to the outlet, misjudging the wire threading in place, and continuing to push forcefully afterward.

[0020] 3. After identifying a high-resistance effective advance state, this invention determines the wire delivery length of the next control window based on the first difference between the effective wire delivery ratio and the lower limit of the effective wire delivery ratio, and the second difference between the load increment and the load rise threshold of the current round. When the high-resistance effective advance state is identified for N consecutive control windows and the effective wire delivery ratio decreases successively, the load increment increases successively, or remains above the load rise threshold, the current wire delivery state is switched to the pipe stagnation treatment state. This can shorten the wire delivery window in advance when the conductor is not completely stuck but the effective wire delivery capacity has decreased and the pipe resistance has increased, reducing the accumulation of pipe compression caused by each round of forward push. When the high-resistance trend continues to worsen, it promptly switches to reverse unloading and stagnation position recording, reducing the probability of the conductor being repeatedly compressed, scraped, and bent at the same bend, joint, or local stagnation position, and providing a more accurate position reference for subsequent pipe inspection. Attached Figure Description

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

[0022] Figure 1 A flowchart of a fully automated intelligent control method for wiring electrical conductors during interior decoration. Figure 2 Flowchart for determining the rebound volume and irreversible infeed volume for this round of shutdown; Figure 3 Flowchart for correction of cumulative effective inlet length and judgment of repeated intervention in the same segment under pipe hysteresis state; Figure 4 Architecture diagram of a fully automated intelligent control system for electrical wiring in building decoration. Detailed Implementation

[0023] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0024] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0025] Example 1: This embodiment provides a fully automated intelligent control method for wiring electrical conductors in building decoration, such as... Figure 1 The diagram shows a flowchart of a fully automated intelligent control method for threading electrical wires in interior decoration. The method operates within an automated threading device consisting of a threading controller, a wire feeding actuator, a wire clamping end, a wire displacement detector, a drive load detector, and a memory. The threading controller can be a programmable logic controller (PLC), an embedded control board, or an industrial computer. The wire feeding actuator can be a servo motor-driven wire feeding wheel assembly. The wire displacement detector can be an coded wheel, a photoelectric displacement sensor, or a visual displacement detector. The drive load detector can be a motor current sampler, a torque sensor, or a driver feedback load acquisition interface. After the electrical wire to be threaded is clamped by the wire clamping end, it enters the inlet of the pre-embedded conduit in the building decoration. The threading controller reads the sensor data according to the control program in the memory, generates control commands, updates the cumulative length, and outputs an abnormal position prompt.

[0026] Before threading, obtain the following parameters: initial control window threading length, effective threading ratio lower limit, load rise threshold, driving load upper limit, minimum effective judgment threading amount, rebound stabilization time, rebound stabilization threshold, maximum rebound observation time, same segment position judgment threshold, and same segment repeated intervention upper limit. The initial control window threading length is the theoretical threading length that can be continuously pushed forward during the first positive threading. It is preset based on the conduit diameter, number of conduit bends, conduit material, conductor outer diameter, number of conductors, threading wheel diameter, and allowable impact level at the construction site. The longer the conduit, the more bends, the thicker the conductor, or the more conductors in the same conduit, the smaller the initial control window threading length should be to observe rebound and load changes earlier. The effective wire delivery ratio lower limit is the proportional threshold for determining whether the wire delivery action translates into actual conduit entry. During presetting, empty conduit and bent conduit calibrations are performed on conduits and conductors of the same specification. The correspondence between the theoretical wire delivery amount and the irreversible conduit entry amount after deducting springback is recorded. A boundary value that can distinguish between normal conduit entry and idle slippage is selected, with a value range between 0 and 1. The load increase threshold is the load change threshold for determining whether the resistance inside the conduit has increased significantly. During presetting, multiple driving loads are first collected during the stable conduit entry phase, and then the upper edge of the normal load fluctuation range is added with a safety margin. The driving load upper limit is the highest load that the wire delivery actuator can withstand. During presetting, it is determined jointly based on the motor's rated torque, the anti-slip capability of the wire delivery wheel, the allowable pressure on the conductor insulation layer, and the upper limit of the conduit's allowable force. The minimum effective judgment wire delivery amount is the minimum theoretical wire delivery amount that allows the calculation of the effective wire delivery ratio. During presetting, it is greater than the length corresponding to the displacement detector's resolution error and the instantaneous meshing error of the wire delivery wheel to avoid misjudgments caused by minor movements. The rebound stabilization time is the continuous time length for observing whether the rebound has stopped. The rebound stabilization threshold is the upper limit of the reverse displacement in the inlet direction that can still be considered stable within a unit sampling interval. Both are determined by calibrating the natural rebound curve after the conductor stops pushing forward. The maximum rebound observation time is the longest observation time allowed to wait for the rebound to end after a single round of pushing forward. The preset time covers the time required for normal conduit compression and release and limits equipment idle waiting. The same segment position judgment threshold is the length range for judging whether two compression lags occur in the same conduit segment. The preset time is determined based on the construction positioning accuracy, conduit bend spacing, and inspection port positioning error. The same segment repeated intervention upper limit is the cumulative intervention upper limit allowed for automatic unloading and retrying near the same position. The preset time is determined based on the conductor insulation layer protection requirements and the conduit blockage risk level.

[0027] After obtaining the above parameters, the cumulative effective entry length is set to zero, the cumulative value of repeated interventions in the same segment is set to zero, and the initial drive load is obtained, which is used as the historical normal load benchmark. The cumulative effective entry length represents the cumulative length of the conductor that is still considered to be stably retained in the pre-buried conduit after deducting the amount of springback, the cumulative amount of backtracking correction, and the backtracking correction of reverse unloading in the current wiring task. It is used to record the progress of the length of the electrical conductor to be wired that has been effectively wired in, and serves as the basis for calculating the remaining target length, judging whether the wired target length has been reached, and locating the location of the pressure stagnation. The larger the cumulative effective entry length, the longer the effective length of the conductor that has been stably entered the pre-buried conduit, and the closer it is to the wired target length. If the cumulative effective entry length increases slowly or is deducted after springback or reverse unloading, it indicates that there are situations such as conductor springback, entry side slippage, compression accumulation in the conduit, or pressure stagnation backtracking in this round or the previous wire feeding. The theoretical wire feeding amount cannot be directly identified as the actual entry length. Setting the cumulative effective conduit length to zero indicates that no effective conduit length has been recorded at the start of the current wiring task. The cumulative value of repeated interventions in the same section represents the cumulative degree of automatic unloading, re-testing, or congestion relief triggered by conduit stagnation within the same conduit section. It records the number of repeated interventions or the intensity of interventions that have occurred near the same suspected jamming location. The larger the cumulative value of repeated interventions in the same section, the more likely the conductor is to experience repeated stagnation near the same location, increasing the risk of conductor insulation damage, worsening conduit blockage, or overload of the wire feeding actuator if automatic wire feeding continues. Setting the cumulative value of repeated interventions in the same section to zero indicates that no conduit stagnation intervention has been recorded at the start of the current wiring task. The initial drive load is collected when the conductor clamping is stable and there is no significant forward push. During the collection process, the wire feeding actuator is first driven into a standby holding state, maintaining a preset clamping pressure between the wire feeding wheel and the conductor to be threaded without outputting conduit ingress direction displacement. Then, the load values ​​for several sampling cycles are continuously read, and anomalies are removed and smoothed from the read load values. When removing outliers, load values ​​that are significantly higher or lower than adjacent sample values ​​and whose duration is shorter than the preset debouncing time are deleted as jump values. During smoothing, the average or moving average of the remaining load values ​​is calculated to obtain the initial drive load. The historical normal load benchmark represents the reference value of normal wire delivery resistance under the current conductor, current clamping state, and current conduit inlet conditions. After the initial drive load is used as the historical normal load benchmark, it is used to determine the unloading target load, so that the reverse unloading process can stop the retraction based on the normal wire delivery resistance, instead of blindly retracting according to a fixed retraction length. When conduit stagnation occurs, the conductor compression is released, while reducing excessive retraction of the conductor length that has already effectively entered the conduit.

[0028] The current control window wire feeding length is set as the initial control window wire feeding length, and wire feeding control commands for pushing the wire forward, stop pushing the wire forward, follow-up release commands for allowing the wire to release and move back towards the inlet, and reverse unloading commands for reverse unloading are established. The current control window wire feeding length represents the stage length of the wire that the wire feeding execution end is allowed to continuously push the wire forward during the current round of wire feeding. It is obtained by reading the initial control window wire feeding length from the wire threading controller before the first round of wire feeding. In subsequent rounds of wire feeding, the current control window wire feeding length is updated by combining the previous round control window wire feeding length with the previous round wire feeding status. When the previous round wire feeding status is a normal effective pushing state, the current control window wire feeding length is maintained. When the previous round wire feeding status is a high-resistance effective pushing state or a pipe pressure stagnation state, the current control window wire feeding length is shortened. When the previous round wire feeding status is an abnormal state on the inlet side, the current control window wire feeding length is not updated based on the theoretical wire feeding amount of that abnormal round. The wire feeding control commands include the wire feeding direction, wire feeding speed, and allowable wire feeding length. The wire threading controller sets the wire feeding direction to the inlet direction, the wire feeding speed to a stable speed matching the conductor specifications, and the allowable wire feeding length to the servo displacement target. The stop forward push command is used to cancel the positive driving force and prevent the wire feeding wheel from continuing to push into the tube. The follow-up release command is used to switch the wire feeding actuator from active forward push to a low-resistance follow-up state or a light clamping release state, so that the slight back movement of the conductor in the inlet direction due to the release of compressive stress in the tube can be accurately captured by the displacement detector. The conductor reverse unloading command is used to drive the wire feeding actuator to retract in the inlet direction when inlet pressure stagnation occurs, and the reverse retraction amount and driving load are simultaneously collected during the retraction process.

[0029] The system obtains the target length for wiring in pre-embedded conduits during building decoration. As the electrical conductors are pushed into the conduits, the remaining target length is obtained by subtracting the current cumulative effective conduit length from the target length. The target length can be imported from the electrical construction drawings, on-site distance measurement results, a conduit list corresponding to the conduit endpoint numbers, or the construction management system. After importation, it is written into the current wiring task by the wiring controller. The remaining target length is used to limit the final stage of the wire delivery distance, preventing wire bending and accumulation caused by continuing to push forward at a larger control window when approaching the conduit outlet or target end.

[0030] The smaller of the remaining target length and the current control window wire feeding length is taken as the allowable wire feeding length for this round. The allowable wire feeding length for this round is the maximum theoretical wire feeding boundary pushed forward in this round. When the remaining target length is large, the current control window wire feeding length is used as the observation period. When the remaining target length is less than the current control window wire feeding length, the remaining target length is used as the termination boundary, so that the control flow automatically shortens the wire feeding distance when it reaches the target length.

[0031] After the start of this round of wire feeding, the theoretical wire feeding amount and the actual wire entering the pipe are accumulated, and the drive load is continuously acquired. At the start of this round of wire feeding, the wire threading controller records the initial pulse count of the encoder at the wire feeding execution end, the initial displacement reading of the wire displacement detector, and the sampling start point of the drive load; during the wire feeding process, the wire threading controller reads the current pulse count of the encoder at the wire feeding execution end, the current displacement reading of the wire displacement detector, and the current drive load reading of the drive load detector according to the sampling period.

[0032] The theoretical wire feeding amount for this round is calculated based on the encoder data at the wire feeding execution end. The wire threading controller subtracts the initial pulse count from the current pulse count of the encoder at the wire feeding execution end to obtain the cumulative pulse difference of the encoder; divides the cumulative pulse difference of the encoder by the number of pulses per revolution of the encoder to obtain the cumulative motor revolutions; divides the cumulative motor revolutions by the transmission ratio at the wire feeding execution end to obtain the cumulative revolutions of the wire feeding wheel; multiplies the cumulative revolutions of the wire feeding wheel by the effective circumference of the wire feeding wheel, and then multiplies by the calibration correction factor of the wire feeding wheel to obtain the theoretical wire feeding amount for this round. The transmission ratio at the wire feeding execution end represents the proportional relationship between the number of motor revolutions and the number of revolutions of the wire feeding wheel; the effective circumference of the wire feeding wheel represents the theoretical length of the wire that the wire travels in one revolution after the wire feeding wheel clamps the wire; the calibration correction factor of the wire feeding wheel represents the ratio between the measured length of the wire travel and the theoretical length of the wire travel during equipment calibration; when no calibration correction is set, the calibration correction factor of the wire feeding wheel is taken as one. The theoretical wire feeding amount for this round obtained thus represents the length of wire output by the wire feeding wheel in the direction of entering the pipe without considering the effects of wire slippage, wire compression, and springback after stopping the feeding.

[0033] The actual conductor insertion depth is calculated based on conductor displacement detection data independent of the feed wheel. When the conductor displacement detector uses a detection wheel encoding method, the threading controller subtracts the initial pulse count of the detection wheel from the current pulse count to obtain the cumulative pulse difference of the detection wheel; divides the cumulative pulse difference by the number of pulses per revolution of the detection wheel to obtain the cumulative revolutions of the detection wheel; multiplies the cumulative revolutions of the detection wheel by the effective circumference of the detection wheel, and then multiplies by the calibration correction factor of the detection wheel to obtain the actual conductor insertion depth. The effective circumference of the detection wheel represents the conductor movement length corresponding to one revolution of the detection wheel after contact with the conductor; the calibration correction factor of the detection wheel represents the ratio between the measured displacement and the theoretical displacement of the conductor during calibration; when no calibration correction is set, the calibration correction factor of the detection wheel is taken as one.

[0034] When the conductor displacement detector uses photoelectric detection, laser ranging, or visual tracking, the threading controller first determines the inlet direction of the pre-buried conduit, then obtains the starting position of the conductor marker at the beginning of this round of wire feeding and the current position at the current sampling point. The distance difference between the current position and the starting position along the inlet direction is taken as the actual conductor inlet amount. If the conductor marker position is represented by two-dimensional or three-dimensional coordinates, the threading controller projects the position change between the current position and the starting position onto the inlet direction and takes the projected length as the actual conductor inlet amount. The threading controller only accumulates the displacement in the inlet direction as the actual conductor inlet amount; the displacement in the entrance direction is not included in the actual conductor inlet amount but is recorded separately as a reverse displacement increment during the follow-up release phase.

[0035] The driving load is uniformly converted into the equivalent pushing force of the wire feeder on the electrical conductor to be threaded, and the driving load, load rise threshold, and driving load upper limit use the same units and calculation methods. When calculating the driving load using motor current, the threading controller subtracts the no-load current from the current motor current to obtain the effective driving current; when the effective driving current is less than zero, it is treated as zero; the effective driving current is multiplied by the motor torque constant to obtain the motor output torque; the motor output torque is multiplied by the transmission ratio at the wire feeding execution end, and then multiplied by the transmission efficiency to obtain the output torque of the wire feeder; the output torque of the wire feeder is divided by the effective radius of the wire feeder to obtain the driving load. The no-load current is obtained by averaging the current when the wire feeder is not subjected to pipe entry resistance and operates at the same wire feeding speed. The motor torque constant can be obtained by dividing the rated torque of the motor by the rated current, or by linearly fitting multiple sets of effective driving currents and measured motor output torques. The effective radius of the wire feeder can be obtained by dividing the effective circumference of the wire feeder by twice pi, or it can be directly measured during equipment calibration.

[0036] When calculating the drive load using driver torque feedback, if the driver outputs the motor output torque, the wire threading controller multiplies the motor output torque by the transmission ratio at the wire feeding end, then multiplies it by the transmission efficiency to obtain the wire feeding wheel output torque. The wire feeding wheel output torque is then divided by the effective radius of the wire feeding wheel to obtain the drive load. If the driver outputs a percentage of the rated torque, the wire threading controller first multiplies the rated torque by the torque percentage to obtain the motor output torque, and then converts it in the same way to obtain the drive load.

[0037] When using a load sensor to calculate the driving load, the wire threading controller subtracts the zero-point output value from the current sensor output value to obtain the effective sensor output value; the effective sensor output value is then multiplied by the range calibration coefficient to obtain the driving load. The zero-point output value is the sensor output value when the wire feed wheel does not exert a pushing force on the conductor, and the range calibration coefficient is obtained by calibrating the sensor output change corresponding to a known pushing force.

[0038] The wire threading controller performs de-jittering and smoothing processing on the continuously acquired drive load. During de-jittering, the controller removes sampled values ​​whose duration is shorter than the preset de-jittering duration and whose deviation from the average of adjacent samples exceeds the preset load jump threshold. During smoothing, the controller averages the most recent consecutive valid sampled values ​​to obtain the drive load used for current state judgment. Through the above processing, the theoretical wire delivery volume, actual conductor insertion volume, and drive load for this round all have clear data sources and calculation paths, which can support the subsequent judgment of effective wire delivery ratio, load increment, abnormal state at the inlet side, and hysteresis state inside the pipe.

[0039] When the theoretical wire delivery amount for this round reaches the allowable wire delivery length for this round, the control window termination condition is met, and a stop-push command is generated. Stopping the push at this point does not indicate an anomaly, but rather that the wire delivery observation action within a control window is complete. The actual length of conductor remaining in the conduit during this round of delivery needs to be determined through bounce observation. When the theoretical wire delivery amount for this round does not reach the allowable wire delivery length, but the drive load reaches the drive load limit, a stop-push command is generated to prevent excessive compression of the conductor insulation or more severe pressure buildup within the conduit.

[0040] When generating the stop-push command, the starting load and the load before stopping the current cycle are recorded. The starting load is the load sampling result obtained within a preset starting sampling interval after the current cable delivery control command is issued; the smoothed load value within this preset starting sampling interval can be taken. The load before stopping the current cycle is the smoothed load value within a sampling interval before the stop-push command is issued. By subtracting the starting load and the load before stopping within the same control window, the load change can be obtained, avoiding misjudgment of normal resistance under different conductor specifications and different conduit friction conditions based solely on absolute load.

[0041] When the control window termination condition is met or the drive load reaches its upper limit, a stop-push command and a follow-up release command are generated, allowing the conductor to move slightly back towards the inlet due to compression and release within the conduit. The stop-push command first stops the forward drive, and the follow-up release command then allows the conductor to move back without being actively dragged. The wire threading controller keeps the conductor displacement detector continuously sampling during command switching to prevent rebound from occurring at the moment of stopping and not being recorded.

[0042] From the moment the follow-up release command is generated, the reverse displacement increment of the conductor moving back towards the pre-buried conduit inlet is continuously acquired. The reverse displacement increment is the increase in the conductor's displacement in the inlet direction at adjacent sampling times. The wire threading controller only accumulates the effective reverse displacement in the inlet direction, filtering out minor positive and negative fluctuations caused by sampling noise. The reverse displacement increment is used to identify the degree of conductor compression and release within the conduit; the greater the rebound, the more length of the theoretically delivered wire in this round has not formed an irreversible entry into the conduit.

[0043] When the reverse displacement increments acquired within the rebound stabilization period are all less than the rebound stabilization threshold, the current rebound cycle is considered complete. Specifically, the wire threading controller continuously checks the reverse displacement increments within the most recent rebound stabilization period from the start of the follow-up release. As long as the reverse displacement increment in any sampling period reaches or exceeds the rebound stabilization threshold, observation continues. Only when the reverse displacement increments are all less than the rebound stabilization threshold throughout the entire continuous observation period is the compression release within the tube considered essentially complete. The cumulative reverse displacement from the generation of the follow-up release command to the determination of the end of the current rebound cycle is used as the rebound stop amount for this cycle. If the maximum rebound observation period is reached before the end of the current rebound cycle is determined, the cumulative reverse displacement within the maximum rebound observation period is used as the rebound stop amount for this cycle, and subsequent judgments are made. This approach effectively deducts normal rebound while preventing the control process from being stalled for an extended period due to continuous wire jitter or sensor noise.

[0044] like Figure 2 The diagram shows the flowchart for determining the current round of stoppage rebound amount and the current round of irreversible pipe insertion amount. After generating the follow-up release command, the reverse displacement increment of the conductor moving back towards the pre-buried conduit inlet is continuously acquired, and it is determined whether all reverse displacement increments acquired within the rebound stabilization time are less than the rebound stabilization threshold. If all reverse displacement increments acquired within the rebound stabilization time are less than the rebound stabilization threshold, it is determined that the current round of rebound has reached a stable state, and the cumulative reverse displacement is taken as the current round of stoppage rebound amount. If there is still a reverse displacement increment not less than the rebound stabilization threshold within the rebound stabilization time, it is further determined whether the maximum rebound observation time has been reached; if the maximum rebound observation time has not been reached, the reverse displacement increment continues to be acquired; if the maximum rebound observation time has been reached, the cumulative reverse displacement within the maximum rebound observation time is taken as the current round of stoppage rebound amount. After obtaining the current round of stoppage rebound amount, the current round of stoppage rebound amount is compared with the current round of actual pipe insertion amount. If the rebound amount during the current round of suspension is not greater than the actual amount of pipe feed during the current round, then the value after deducting the rebound amount during the current round from the actual amount of pipe feed during the current round is taken as the unrecoverable amount of pipe feed during the current round. If the rebound amount during the current round of suspension is greater than the actual amount of pipe feed during the current round, then the unrecoverable amount of pipe feed during the current round is recorded as zero, and the portion of the rebound amount during the current round of suspension that exceeds the actual amount of pipe feed during the current round is generated as the cumulative rollback correction amount.

[0045] Compare the current round of stoppage rebound with the current round of actual conduit insertion. When the current round of stoppage rebound is not greater than the current round of actual conduit insertion, the value after deducting the current round of stoppage rebound from the current round of actual conduit insertion is taken as the current round of irrecoverable conduit insertion. The current round of irrecoverable conduit insertion represents the effective length remaining in the pre-buried conduit after stopping and releasing, and is the basis for updating the cumulative effective conduit insertion length. When the current round of stoppage rebound is greater than the current round of actual conduit insertion, the current round of irrecoverable conduit insertion is recorded as zero, and the portion of the current round of stoppage rebound exceeding the current round of actual conduit insertion is taken as the cumulative backtracking correction. The excess portion indicates that the conductors previously included in the cumulative effective conduit insertion length have experienced additional backtracking, which needs to be deducted from the current cumulative effective conduit insertion length. After deducting the cumulative backtracking correction, if the result is less than zero, the cumulative effective conduit insertion length is corrected to zero to avoid negative cumulative length values ​​that would affect the calculation of the remaining target length.

[0046] When the theoretical feed rate in this round is not less than the minimum effective feed rate, the irreversible feed rate in this round is divided by the theoretical feed rate to obtain the effective feed rate in this round. The load increment in this round is obtained by subtracting the initial load from the load before the round stops. The effective feed rate in this round reflects the degree to which theoretical forward pushing is converted into actual effective feed rate, while the load increment in this round reflects the degree of resistance increase within the same control window. Using both together can distinguish between normal advance, high-resistance advance, inlet-side anomalies, and in-tube pressure stagnation.

[0047] When the effective wire delivery ratio in this round is not less than the lower limit of the effective wire delivery ratio and the load increment in this round is less than the load rise threshold, it is identified as a normal effective advance state, and the irreversible insertion amount in this round is counted as the effective advance length in this round and included in the cumulative effective insertion length. During the counting process, the wire threading controller first reads the cumulative effective insertion length before counting, then adds the irreversible insertion amount in this round to the cumulative effective insertion length before counting to obtain the cumulative effective insertion length after counting, and generates a counted mark for the wire delivery record in this round to avoid the same irreversible insertion amount in the same round being repeatedly accumulated in subsequent arrival judgments. Subsequently, the historical normal load benchmark is updated based on the load before this round stops. When updating the historical normal load benchmark, the original historical normal load benchmark and the load before this round stops are merged according to a preset weight, so that the historical normal load benchmark gradually approaches the normal friction level of the current conduit and the current conductor.

[0048] When the effective feed ratio of this round is not less than the lower limit of the effective feed ratio and the load increment of this round is not less than the load rise threshold, it is identified as a high-resistance effective advance state, and the irreversible advance of this round is included in the cumulative effective advance length. Upon inclusion, a mark indicating that the advance has already been included in this round is generated. Subsequent checks and window adjustments are only performed based on the cumulative effective advance length after inclusion, without further accumulation of the irreversible advance of this round. Subsequently, the effective feed ratio of this round is subtracted from the lower limit of the effective feed ratio to obtain the first difference, and the load increment of this round is subtracted from the load rise threshold to obtain the second difference. The first difference represents the margin of the effective feed ratio relative to the minimum effective advance requirement; the smaller the first difference, the closer the effective advance of this round is to the inefficient boundary. The second difference represents the degree to which the load increment of this round exceeds the load rise threshold; the larger the second difference, the more significant the increase in pipe resistance.

[0049] The next round of control window cable delivery length is determined based on the first and second differences. The cable threading controller first determines the first risk coefficient based on the first difference. The first difference benchmark is the difference obtained by subtracting the lower limit of the effective cable delivery ratio from one. Dividing the first difference by the first difference benchmark yields the effective advance margin ratio, and then subtracting the effective advance margin ratio from one yields the first risk coefficient. The value range of the above risk coefficient is from zero to one, where zero represents the lowest risk and one represents the highest risk. That is, when the first risk coefficient is less than zero, it is treated as zero, and when the first risk coefficient is greater than one, it is treated as one. The smaller the first difference, the smaller the effective advance margin ratio, and the larger the first risk coefficient. Then, the second risk coefficient is determined based on the second difference. The second difference benchmark is the remaining tolerable load increment obtained by subtracting the starting load of this round from the upper limit of the drive load, and then subtracting the load rise threshold. When the second difference benchmark is not greater than zero, it means that there is no sufficient load judgment margin between the starting load of this round and the upper limit of the drive load, and the second risk coefficient is recorded as one. When the second difference benchmark is greater than zero, the second difference is divided by the second difference benchmark to obtain the second risk coefficient. If the second risk coefficient is less than zero, it is treated as zero; if the second risk coefficient is greater than one, it is treated as one. The larger the second difference, the larger the second risk coefficient. The larger of the first and second risk coefficients is used as the window shortening risk coefficient, and the window shortening ratio is determined based on the window shortening risk coefficient. The window shortening ratio consists of the base shortening ratio and the risk-added shortening ratio. The risk-added shortening ratio is obtained by multiplying the window shortening risk coefficient by the maximum added shortening ratio. When the sum of the base shortening ratio and the risk-added shortening ratio is greater than the preset maximum shortening ratio, the preset maximum shortening ratio is used as the window shortening ratio. A base shortening ratio greater than zero and a preset maximum shortening ratio greater than zero and less than one ensures that the wire length of the next round of control window can be shortened but will not be shortened to zero all at once. The current control window wire length is shortened according to the window shortening ratio to obtain the candidate next round control window wire length. When the candidate next-round control window wire length is not less than the minimum control window wire quantity, the candidate next-round control window wire length is used as the next-round control window wire length; when the candidate next-round control window wire length is less than the minimum control window wire quantity, the minimum control window wire quantity is used as the next-round control window wire length. The minimum control window wire quantity is less than or equal to the minimum effective judgment wire quantity; when the actual wire quantity in the next round is less than the minimum effective judgment wire quantity, the effective wire quantity ratio for this round is not calculated, and the abnormal state on the inlet side or the pressure stagnation state in the pipe is identified according to whether the drive load has reached the upper limit of the drive load based on the small wire quantity branch.

[0050] When a high-resistance effective propulsion state is identified in N consecutive control windows, and the effective wire delivery ratio in the current round decreases successively in the N consecutive control windows, and the load increment in the current round increases successively or is not less than the load rise threshold, the wire threading controller will switch the current wire delivery state from the high-resistance effective propulsion state to the in-pipe hysteresis processing state, and use the cumulative effective pipe length before switching to the in-pipe hysteresis processing state as the hysteresis position reference. Here, N is the number of hysteresis trend judgment windows, representing the number of consecutive control windows used to identify whether the high-resistance effective propulsion continues to deteriorate. N is an integer greater than or equal to two pre-stored in the wire threading controller. During the equipment commissioning phase, N is set according to the pre-buried conduit length, number of bends, outer diameter of the conductor, number of conductors, and friction conditions of the conduit inner wall. The longer the conduit, the more bends, the thicker the conductor, or the more conductors in the same conduit, the smaller the value of N should be to improve the hysteresis identification sensitivity. When the conduit is short, there are few bends, or the conductor is thin, the value of N should be larger to reduce misjudgments caused by occasional friction fluctuations. This transition action indicates that the conductor will no longer be pushed forward according to the high-resistance effective advancement window, but will instead trigger reverse unloading and stagnation position recording; for irreversible in-pipe quantities that have already been counted in the previous high-resistance effective advancement window, they will not be deducted or counted again due to the stagnation treatment state in the in-pipe transition.

[0051] When the theoretical wire feeding amount in this round is not less than the minimum effective wire feeding amount, the wire threading controller identifies the wire feeding status of this round based on the effective wire feeding ratio, the load increment, and whether the drive load has reached the upper limit of the drive load. If the drive load reaches the upper limit of the drive load, it no longer waits for the combined judgment of the effective wire feeding ratio and the load increment of this round, and directly identifies it as a state of stagnation in the tube, in order to avoid further pushing forward and causing damage to the conductor insulation layer, increased stagnation in the tube, or overload of the wire feeding execution end. If the drive load has not reached the upper limit of the drive load, and the effective wire feeding ratio in this round is less than the lower limit of the effective wire feeding ratio, and the load increment in this round is less than the load rise threshold, it is identified as an abnormal state on the inlet side. This state indicates that the wire feeding wheel has generated the theoretical wire feeding amount, but the conductor has not formed a sufficient effective amount of wire entering the tube, and at the same time, the drive load has not shown a significant increase corresponding to the stagnation in the tube. Therefore, it prioritizes addressing inlet side problems such as wire feeding wheel slippage, insufficient clamping pressure, conductor displacement detection failure, conductor inlet posture deviation, or misalignment of the inlet guide. If the driving load does not reach the upper limit of the driving load, and the effective wire delivery ratio in this round is less than the lower limit of the effective wire delivery ratio, and the load increment in this round is not less than the load rise threshold, then it is identified as a stagnant state in the pipe. This state indicates that the conductor has not formed a sufficient effective amount of wire entering the pipe, and the wire delivery resistance has increased significantly, which is consistent with the characteristics of the conductor being compressed and accumulated at the bend, joint, local deformation section or foreign object obstruction of the pre-buried conduit.

[0052] When the theoretical wire delivery amount in this round is less than the minimum effective wire delivery amount, the wire threading controller does not calculate the effective wire delivery ratio for this round, and only identifies the condition based on whether the drive load has reached the drive load limit. If the drive load reaches the drive load limit, it is identified as a pressure stagnation state inside the pipe; if the drive load does not reach the drive load limit, it is identified as an abnormal state on the inlet side. This avoids miscalculation of the effective wire delivery ratio when the wire delivery amount is too small, the displacement detection resolution is insufficient, or the sampling error accounts for a high proportion, while retaining rapid protection judgment against the risk of pressure stagnation under high load.

[0053] When a valid advance state is identified, the threading controller reads the counted advance of this round. If the irreversible advance of this round has already been counted as a valid advance in the normal or high-resistance effective advance state and included in the cumulative valid advance length, it will not be counted again. Only the cumulative valid advance length after being counted and the threading target length will generate a continue feeding command or a stop-to-position command. If the cumulative valid advance length is less than the threading target length, a continue feeding command will be generated and the system will enter the next control window; if the cumulative valid advance length reaches the threading target length, a stop-to-position command will be generated, automatic feeding will stop, and the threading position result will be output.

[0054] When an abnormal state is identified at the inlet side, the theoretical wire delivery amount, actual wire insertion amount, and irreversible insertion amount of the current round are not included in the cumulative effective insertion length, and the use of these quantities to update the cumulative effective insertion length is stopped. The wire threading controller then generates a wire clamping retest command to re-establish clamping or contact between the electrical wire to be threaded and the wire delivery actuator. During the clamping retest, the wire delivery actuator is released to the inspection state, then the wire is re-clamped according to the preset clamping pressure, and the clamping pressure or motor holding load is read to see if it is within the acceptable range. Subsequently, a wire displacement detection retest command is generated to re-establish the wire displacement detection state. During the displacement detection retest, the wire threading controller clears the abnormal sampling buffer of the current round and recalibrates the zero point, direction, and sampling state of the wire displacement detector.

[0055] After completing the clamping and displacement detection retest, a small-amplitude trial movement command is generated, causing the electrical conductor to be threaded to perform one forward trial movement and one reverse trial movement according to the preset small-amplitude trial movement displacement. The preset small-amplitude trial movement displacement is determined before execution by the conductor's outer diameter, the gap of the inlet guide, and the displacement detection resolution. Its length is sufficient to be reliably identified by the displacement detector, but insufficient to cause the conductor to form a new significant compression inside the conduit. If a displacement in the conduit entry direction is obtained during the forward trial movement and a displacement in the inlet direction is obtained during the reverse trial movement, the conductor displacement detection is deemed valid, and a continue wire feeding command is generated. If no displacement corresponding to the trial movement direction is obtained, automatic wire feeding stops, and an inlet-side detection anomaly result is output. The inlet-side detection anomaly result may include information such as clamping anomaly, displacement detection anomaly, conductor inlet offset anomaly, and a suggestion to manually check the inlet guide status, facilitating quick handling by construction personnel.

[0056] When a stagnation state is identified, the irreversible amount of wire fed into the conduit in this round is not included in the cumulative effective wire feeding length. The forward pushing of the conductor based on the theoretical wire feeding amount of this round is stopped, and the cumulative effective wire feeding length corresponding to the identification of the stagnation state is taken as the location of this stagnation occurrence. The wire threading controller determines the unloading target load based on the starting load of this round, the historical normal load benchmark, and the preset unloading margin. Specifically, the wire threading controller first compares the starting load of this round and the historical normal load benchmark, taking the larger value as the unloading reference load; then, it adds the preset unloading margin to the unloading reference load to obtain the unloading target load. The preset unloading margin is determined by the normal load fluctuation amplitude, load sampling error, and the control accuracy of the wire feeding execution end. Using the larger value as the unloading reference load avoids excessive backtracking caused by the unloading target load being lower than the normal friction level under the current conduit conditions; adding the preset unloading margin to the unloading reference load ensures that reverse unloading stops when the load approaches the normal wire feeding resistance, while retaining a certain margin against sampling fluctuations.

[0057] like Figure 3 The diagram shows the flowchart for correcting the cumulative effective inlet length and judging repeated interventions in the same section under the condition of pipe stagnation. After generating the stop reverse unloading command, if the reverse backtracking amount exceeds the unrecoverable inlet length of this round, the excess part will be deducted from the cumulative effective inlet length; if it does not exceed, the position deviation calculation will proceed directly. Subsequently, the cable controller determines whether the current stagnation belongs to the same conduit section based on the position deviation between the current stagnation location and the previous stagnation location record. When the previous stagnation location record is empty, or the position deviation is greater than the same section position judgment threshold, the previous stagnation location record is written, and the cumulative value of repeated interventions in the same section is set to the initial intervention value; when the position deviation is not greater than the same section position judgment threshold, the increase in the current repeated intervention in the same section is determined, and the cumulative value of repeated interventions in the same section is updated. If the updated cumulative value of repeated interventions in the same section reaches the upper limit of repeated interventions in the same section, automatic cable feeding is stopped and the conduit inspection position reference is output; if it does not reach the upper limit, subsequent control window processing continues.

[0058] A reverse unloading command is generated to retract the electrical conductor to be threaded towards the conduit inlet, simultaneously acquiring the reverse retraction amount and drive load. The reverse retraction amount is determined by the difference between the current displacement reading of the conductor displacement detector and the displacement reading at the start of reverse unloading. The threading controller prioritizes the displacement detection result that reflects the actual retraction of the conductor and uses the encoder result for consistency verification. During reverse unloading, if the drive load decreases to the unloading target load, it indicates that the compression resistance inside the conduit has been released to near the normal range, and the threading controller generates a stop reverse unloading command. If the drive load has not yet decreased to the unloading target load but the reverse retraction amount reaches the theoretical feed amount of this round, it indicates that the theoretical forward push caused by this round has been basically withdrawn, and continued retraction may affect the previous effective conduit length, so a stop reverse unloading command is also generated. If the reverse retraction amount exceeds the irrecoverable conduit feed amount of this round, the excess portion is deducted from the cumulative effective conduit length, and the cumulative effective conduit length is still not less than zero after deduction. This process ensures that the pressure hysteresis treatment can both release the pressure inside the conduit and maintain the accuracy of the cumulative feed.

[0059] After the stagnation unloading is completed, the positional deviation between the current stagnation location and the previous stagnation location record is calculated. If the previous stagnation location record is empty, or the positional deviation is greater than the same segment position judgment threshold, the current stagnation location is written into the previous stagnation location record, and the cumulative value of repeated interventions in the same segment is set to the initial intervention value. An empty previous stagnation location record indicates that stagnation has occurred for the first time in the current wiring task; a positional deviation greater than the same segment position judgment threshold indicates that the current stagnation is not in the same conduit segment as the historical stagnation, and the wiring controller treats it as a new stagnation segment. The initial intervention value represents the basic cumulative amount of automatic intervention that has occurred once in this segment, given by the preset intervention counting rules in the memory.

[0060] When the position deviation is not greater than the same segment position judgment threshold, the wiring controller calculates the increase in the amount of repeated intervention in the same segment based on the position deviation, reverse back-off amount, drive load at the time of unloading stop, and whether the unloading has reached the unloading target load. Before calculation, the wiring controller obtains the basic increase value, the position deviation high overlap threshold, the back-off amount high proportion threshold, the back-off amount medium proportion threshold, the residual load height difference threshold, the position item intervention value, the back-off item intervention value, the residual load item intervention value, the unloading failure item intervention value, and the preset single increase limit. The above thresholds and intervention values ​​are preset during the equipment debugging phase, and are determined by trial wiring data of the same specification wire, the same specification pre-buried conduit, and conduits with different bending degrees. The situation where the wire can be stably restored through automatic unloading corresponds to a lower intervention value, and the situation where there is repeated pressure at the same position, a large reverse back-off amount is required, or the load is still high after unloading corresponds to a higher intervention value. The basic increase value is first used as the starting value of the increase in the amount of repeated intervention in the same segment. The basic increase value represents the cumulative intervention value that will inevitably increase when pressure occurs again in the same conduit segment, and it is used to reflect that repeated pressure has occurred in the same segment. The intervention value for the position item is determined based on the position deviation. The high overlap threshold for position deviation is lower than the same segment position judgment threshold, used to distinguish between highly overlapping stagnation positions and stagnation positions in the same segment but not completely overlapping. When the position deviation is not greater than the high overlap threshold, it indicates that the current stagnation position highly overlaps with the previous stagnation position, and the first position item intervention value is increased; when the position deviation is greater than the high overlap threshold but not greater than the same segment position judgment threshold, it indicates that the current stagnation still belongs to the same pipeline segment but the degree of position overlap is low, and the second position item intervention value is increased. The first position item intervention value is greater than the second position item intervention value. The intervention value for the reversal item is determined based on the reverse reversal amount. The reversal ratio between the reverse reversal amount and the theoretical delivery amount in this round is calculated. The high ratio threshold for the reversal amount is greater than the medium ratio threshold for the reversal amount. If the rollback percentage is not less than the high rollback percentage threshold, it indicates that a rollback close to the theoretical wire delivery amount for this round is needed to stop reverse unloading, and the first rollback intervention value is increased; if the rollback percentage is less than the high rollback percentage threshold but not less than the medium rollback percentage threshold, the second rollback intervention value is increased; if the rollback percentage is less than the medium rollback percentage threshold, the rollback intervention value is not increased. The first rollback intervention value is greater than the second rollback intervention value. The residual load intervention value is determined based on the drive load at the time of unloading stop. The residual load difference is obtained by subtracting the unloading target load from the drive load at the time of unloading stop. If the residual load difference is greater than the residual load height difference threshold, it indicates that there is still significant residual resistance after unloading, and the wire threading controller increases the first residual load intervention value; if the residual load difference is greater than zero and not greater than the residual load height difference threshold, it indicates that there is still slight residual resistance after unloading, and the wire threading controller increases the second residual load intervention value; if the residual load difference is not greater than zero, the residual load intervention value is not increased. The first residual load intervention value is greater than the second residual load intervention value. The unloading failure intervention value is determined based on whether the unloading target load has been reached.If the reverse unloading stops because the reverse backoff amount reaches the theoretical line delivery amount for this round, but the driving load has not yet decreased to the unloading target load, it is determined that the unloading has not reached the unloading target load, and the unloading failure intervention value is increased; if the driving load has decreased to the unloading target load, the unloading failure intervention value is not increased. The basic increase value, position intervention value, backoff intervention value, residual load intervention value, and unloading failure intervention value are added together to obtain the increase amount of the same segment repeated intervention; when the sum is greater than the preset single increase amount upper limit, the preset single increase amount upper limit is used as the increase amount of the same segment repeated intervention. Through this calculation method, the smaller the position deviation, the larger the position intervention value; the closer the reverse backoff amount is to the theoretical line delivery amount for this round, the larger the backoff intervention value; the higher the driving load when unloading stops, the larger the residual load intervention value; when the unloading has not reached the unloading target load, an additional unloading failure intervention value is added, so that the increase amount of the same segment repeated intervention increases with the degree of pressure repetition and the degree of unloading difficulty.

[0061] The cumulative value of repeated interventions in the same segment is updated based on the increase in the amount of repeated interventions in this segment. When the updated cumulative value of repeated interventions in the same segment reaches the upper limit of repeated interventions in the same segment, automatic wire feeding stops, and the location of the current stagnation or the conduit segment formed by the current stagnation location is output as a conduit inspection location reference. The conduit inspection location reference can be converted from the cumulative effective conduit length to the length from the inlet end, or it can be combined with the conduit path, bend location, junction box location, and construction drawings to generate suggested inspection sections. If the updated cumulative value of repeated interventions in the same segment does not reach the upper limit of repeated interventions in the same segment, the wire feeding controller re-determines the wire feeding length of the next control window based on the load status after stagnation treatment and the remaining target length, and continues to attempt wire feeding with a shorter control window.

[0062] Example 2: This example provides a fully automated intelligent control system for wiring electrical wires in building decoration, such as... Figure 4 The diagram shows the architecture of a fully automated intelligent control system for electrical wiring in building decoration, which includes a data acquisition module, a stop-feed / springback analysis module, a wire feeding result identification module, an effective propulsion execution module, an entry anomaly execution module, and an in-pipe pressure lag execution module.

[0063] The data acquisition module is used to obtain the target length of the wires to be threaded into the pre-embedded conduit in building decoration, and to obtain the theoretical wire delivery amount, the actual wire insertion amount and the driving load in this round according to the control window during the process of pushing the electrical wires to be threaded into the pre-embedded conduit.

[0064] The stop-and-feed springback analysis module is used to generate stop-and-push commands and follow-up release commands when the control window end conditions are met or the drive load reaches the upper limit of the drive load. This allows the conductor to move back slightly towards the inlet due to the compression and release inside the tube, and to obtain the stop-and-feed springback amount formed by the slight back movement in this round.

[0065] The wire delivery result identification module is used to determine the unrecoverable wire delivery volume in this round based on the actual wire delivery volume and the rebound volume during the current round of delivery stoppage. Based on the correspondence between the unrecoverable wire delivery volume and the theoretical wire delivery volume in this round, as well as the change in driving load, the module identifies the wire delivery result in this round as an effective propulsion state, an abnormal state on the inlet side, or a stagnation state inside the pipe.

[0066] The effective advancement execution module is used to include the current unrecoverable pipe insertion quantity in the cumulative effective pipe insertion length when the effective advancement state is identified, and to generate a continue delivery command or a stop delivery command based on the cumulative effective pipe insertion length and the target threading length.

[0067] The entry anomaly execution module is used to exclude the theoretical wire delivery volume, actual wire entry volume, and irrecoverable wire entry volume of the current round from the cumulative effective wire entry length when an entry anomaly is identified. It also generates a conductor displacement detection retest command and a wire delivery clamp retest command.

[0068] The in-pipe pressure hysteresis execution module is used to prevent the irrecoverable in-pipe flow from being included in the cumulative effective in-pipe flow length when the in-pipe pressure hysteresis state is identified. It stops pushing the conductor forward based on the theoretical wire delivery amount of the current round and generates a conductor reverse unloading command and pressure position record.

Claims

1. A fully automated intelligent control method for wiring electrical conductors in building decoration, characterized in that, Includes the following steps: Obtain the target length of the wires to be threaded into the pre-embedded conduit for building decoration, and during the process of pushing the electrical wires to be threaded into the pre-embedded conduit, obtain the theoretical wire delivery amount, the actual wire insertion amount and the driving load of this round according to the control window; When the control window end condition is met or the drive load reaches the drive load limit, a stop push command and a follow-up release command are generated, so that the conductor can move back slightly towards the inlet due to the compression and release inside the tube, and the current round stop springback amount formed by the slight back movement is obtained. The irrecoverable infeed volume for this round is determined based on the actual infeed volume and the rebound volume during the stop-feeding phase. Based on the correspondence between the irrecoverable infeed volume and the theoretical wire delivery volume for this round, as well as the changes in the driving load, the wire delivery result for this round is identified as an effective propulsion state, an abnormal state on the inlet side, or a stagnation state inside the pipe. When the current unrecoverable insertion length is identified as being in a valid advance state, the current unrecoverable insertion length is included in the cumulative valid insertion length, and a continue delivery command or a stop delivery command is generated based on the cumulative valid insertion length and the target threading length. When an abnormal state is identified at the inlet side, the theoretical wire delivery volume, actual wire entry volume, and irrecoverable wire entry volume of this round are not included in the cumulative effective wire entry length, and a conductor displacement detection retest command and a wire delivery clamp retest command are generated. When the pipe is identified as being under pressure, the irreversible amount of wire fed into the pipe in this round is not included in the cumulative effective length of wire fed into the pipe. The wire is stopped from being pushed forward based on the theoretical amount of wire fed into the pipe in this round, and a reverse unloading command for the wire and a pressure position record are generated.

2. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 1, characterized in that, Before obtaining the target length of the pre-embedded conduit for building decoration, the following steps are also included: Get the initial control window feed length, effective feed ratio lower limit, load rise threshold, drive load upper limit, minimum effective judgment feed amount, rebound stabilization time, rebound stabilization threshold, maximum rebound observation time, same segment position judgment threshold, and same segment repeated intervention upper limit; Set the cumulative effective pipe length to zero, set the cumulative value of repeated interventions in the same segment to zero, and obtain the initial drive load, using the initial drive load as the historical normal load benchmark. Set the current control window wire feeding length to the initial control window wire feeding length, and establish a wire feeding control command for pushing the wire forward, a stop pushing command for stopping the pushing forward, a follow-up release command for allowing the wire to release and move back in the inlet direction, and a wire reverse unloading command for reverse unloading.

3. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 1, characterized in that, The process of obtaining the theoretical wire delivery amount, actual wire insertion amount, and drive load for this round according to the control window includes: The remaining target length is obtained by subtracting the current cumulative effective pipe entry length from the target threading length; The smaller value between the remaining target length and the current control window wire length is taken as the allowable wire length for this round; After the start of this round of wire feeding, the theoretical wire feeding amount and the actual wire entering the pipe are accumulated, and the driving load is continuously acquired; When the theoretical wire delivery amount in this round reaches the allowable wire delivery length in this round, it is determined that the control window end condition is met, and a stop push command is generated; When the theoretical wire delivery amount in this round does not reach the allowable wire delivery length in this round, but the driving load reaches the upper limit of the driving load, a stop push command is generated. When generating the stop push command, record the starting load of this round and the load before the stop of this round.

4. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 1, characterized in that, The step of obtaining the rebound amount of the current round of stopping caused by the minute backshift includes: After generating the stop forward push command, a follow-up release command is generated, enabling the conductor to be released and moved back towards the pre-buried conduit inlet. From the moment the follow-up release command is generated, the reverse displacement increment of the conductor moving back towards the inlet of the pre-embedded conduit is continuously acquired; When the reverse displacement increments obtained within the rebound stabilization period are all less than the rebound stabilization threshold, the current rebound is determined to be over. The cumulative reverse displacement from the generation of the follow-up release command to the determination of the end of this round of rebound will be used as the rebound amount of this round of stop delivery; If the current rebound cycle is not determined to be over after the maximum rebound observation time is reached, the cumulative reverse displacement within the maximum rebound observation time will be used as the rebound amount for this cycle.

5. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 1, characterized in that, The determination of the irrecoverable infeed volume for this round based on the actual infeed volume and the rebound volume during the current shutdown includes: Compare the amount of rebound material released during this round of shutdown with the actual amount of material fed into the tube during this round; When the amount of rebound during the current round of suspension is not greater than the actual amount of pipe insertion during the current round, the value after deducting the amount of rebound during the current round from the actual amount of pipe insertion during the current round shall be taken as the irrecoverable amount of pipe insertion during the current round. When the rebound amount of the current round of suspension is greater than the actual amount of the current round of pipe insertion, the irrecoverable amount of the current round of pipe insertion is recorded as zero, and the portion of the rebound amount of the current round of suspension that exceeds the actual amount of the current round of pipe insertion is taken as the cumulative backoff correction amount; The cumulative rollback correction amount is subtracted from the current cumulative effective inlet length, and the cumulative effective inlet length is corrected to zero when the subtraction result is less than zero.

6. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 1, characterized in that, The process of identifying the current round's cable delivery result as an effective propulsion state, an abnormal state on the inlet side, or a state of pressure stagnation in the pipe based on the correspondence between the irreversible inlet cable volume and the theoretical cable delivery volume, and changes in the driving load, includes: When the theoretical wire delivery amount in this round is not less than the minimum effective judgment wire delivery amount, calculate the ratio of the irrecoverable wire delivery amount in this round to the theoretical wire delivery amount in this round to obtain the effective wire delivery ratio in this round, and calculate the difference between the load before the end of this round and the starting load of this round to obtain the load increment in this round. When the effective line delivery ratio in this round is not less than the lower limit of the effective line delivery ratio and the load increment in this round is less than the load rise threshold, it is identified as a normal effective advance state. The irreversible pipe entry volume in this round is included in the cumulative effective pipe entry length, and the historical normal load benchmark is updated according to the load before this round stops. When the effective wire feed ratio in this round is not less than the lower limit of the effective wire feed ratio and the load increment in this round is not less than the load rise threshold, it is identified as a high resistance effective push state. The irreversible pipe entry amount in this round is included in the cumulative effective pipe entry length. The wire feed length of the control window in the next round is determined based on the difference between the effective wire feed ratio in this round and the lower limit of the effective wire feed ratio, as well as the difference between the load increment in this round and the load rise threshold. When the effective line feed ratio in this round is less than the lower limit of the effective line feed ratio and the load increment in this round is less than the load rise threshold, it is identified as an abnormal state on the inlet side. When the effective line feed ratio in this round is less than the lower limit of the effective line feed ratio and the load increment in this round is not less than the load rise threshold, or when the driving load reaches the upper limit of the driving load, it is identified as a hysteresis state in the pipe. When the theoretical feed rate in this round is less than the minimum effective feed rate, if the driving load reaches the upper limit of the driving load, it is identified as a stagnation state inside the pipe; if the driving load does not reach the upper limit of the driving load, it is identified as an abnormal state on the inlet side.

7. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 6, characterized in that, The step of determining the next round's control window cable length based on the difference between the current round's effective cable delivery ratio and its lower limit, and the difference between the current round's load increment and its load rise threshold, includes: After identifying the high-resistance effective propulsion state, calculate the first difference between the effective wire delivery ratio and the lower limit of the effective wire delivery ratio in this round, and calculate the second difference between the load increment in this round and the load rise threshold. The next round of control window wire feeding length is determined based on the first difference and the second difference, so that the next round of control window wire feeding length is less than the current control window wire feeding length; Wherein, the smaller the first difference, the smaller the wire length of the next round control window; the larger the second difference, the smaller the wire length of the next round control window. If the current line delivery state is identified as high resistance effective propulsion state in N consecutive control windows, and the effective line delivery ratio in the current round decreases successively in N consecutive control windows, and the load increment in the current round increases successively or is not less than the load rise threshold, the current line delivery state is switched to the pipe stagnation state, and the cumulative effective pipe entry length before switching to the pipe stagnation state is used as the stagnation position reference.

8. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 6, characterized in that, When an abnormal state is identified on the inlet side, the generation of conductor displacement detection retest command and wire clamp retest command includes: Stop including the theoretical wire delivery volume, actual wire insertion volume, and irreversible insertion volume in the current round in the cumulative effective insertion length; Generate a wire feeding clamp retest command to re-establish the clamping or contact state between the electrical wire to be threaded and the wire feeding execution end; Generate a re-measurement command for conductor displacement detection to re-establish the conductor displacement detection status; Generate a small-amplitude trial movement command to cause the electrical wire to be threaded to perform one forward trial movement and one reverse trial movement according to the preset small-amplitude trial movement displacement; If a displacement in the inlet direction is detected during the forward test and a displacement in the inlet direction is detected during the reverse test, the conductor displacement detection is deemed valid, and a command to continue sending the conductor is generated. If the displacement corresponding to the test direction is not obtained, the automatic wire feeding will stop and the abnormal detection result at the inlet side will be output.

9. The fully automatic intelligent control method for wiring electrical conductors in building decoration according to claim 6, characterized in that, When a pipe hysteresis state is identified, the generation of the conductor reverse unloading command and hysteresis position record includes: Stop including the irreversible inlet length in the current round in the cumulative effective inlet length, and use the cumulative effective inlet length corresponding to the time when it is identified as an inlet stagnation state as the location where the stagnation occurred. The target unloading load is determined based on at least one of the following: the initial load of this round, the historical normal load benchmark, and the preset unloading margin. Generate a reverse unloading command for the conductor, causing the electrical conductor to be installed to retract towards the entrance of the pre-buried conduit, and simultaneously acquire the reverse retraction amount and the driving load; When the drive load drops to the unloading target load, or the reverse backoff amount reaches the theoretical wire delivery amount of this round, a stop reverse unloading command is generated; If the reverse back-off amount exceeds the irreversible in-pipe length in this round, the excess portion will be deducted from the cumulative effective in-pipe length. Calculate the positional deviation between the current location of hysteresis and the previous recorded location of hysteresis; When the previous stagnation location record is empty, or the location deviation is greater than the same segment location judgment threshold, the current stagnation location is written into the previous stagnation location record, and the cumulative value of repeated interventions in the same segment is set to the initial intervention value. When the position deviation is not greater than the same segment position judgment threshold, the increase in the same segment repeated intervention is determined based on the position deviation, the reverse backoff amount, the driving load when unloading stops, and whether the unloading has reached the unloading target load. Wherein, the smaller the position deviation, or the closer the reverse retreat amount is to the theoretical wire delivery amount of this round, or the higher the driving load when the unloading stops, or the unloading does not reach the unloading target load, the greater the increase in the current segment repeated intervention. The cumulative value of repeated intervention in the same segment is updated according to the increase in the amount of repeated intervention in the same segment. When the updated cumulative value of repeated intervention in the same segment reaches the upper limit of repeated intervention in the same segment, the automatic line feeding is stopped, and the location of the current stagnation or the pipeline section formed by the location of the current stagnation is output as the reference for pipeline inspection location.

10. A fully automated intelligent control system for electrical wiring in building decoration, characterized in that: include: The data acquisition module is used to obtain the target length of the wires to be threaded into the pre-embedded conduit in building decoration, and to obtain the theoretical wire delivery amount, the actual wire insertion amount and the driving load in this round according to the control window during the process of pushing the electrical wires to be threaded into the pre-embedded conduit. The stop-and-feed springback analysis module is used to generate a stop-and-push command and a follow-up release command when the control window end condition is met or the drive load reaches the upper limit of the drive load, so that the conductor can move back slightly towards the inlet due to the compression and release inside the tube, and obtain the stop-and-feed springback amount formed by the slight back movement in this round. The wire delivery result identification module is used to determine the unrecoverable wire delivery volume in this round based on the actual wire delivery volume and the rebound volume after the stop delivery in this round. Based on the correspondence between the unrecoverable wire delivery volume and the theoretical wire delivery volume in this round, as well as the change in the driving load, the module identifies the wire delivery result in this round as an effective propulsion state, an abnormal state on the inlet side, or a stagnation state in the pipe. The effective advancement execution module is used to include the current unrecoverable pipe insertion amount in the cumulative effective pipe insertion length when the effective advancement state is identified, and to generate a continue delivery instruction or a stop delivery instruction based on the cumulative effective pipe insertion length and the target length of the threading. The entry anomaly execution module is used to prevent the theoretical wire delivery volume, actual wire entry volume, and irrecoverable wire entry volume of the current round from being included in the cumulative effective wire entry length when an entry anomaly is identified. It also generates a conductor displacement detection retest command and a wire delivery clamp retest command. The in-pipe pressure hysteresis execution module is used to prevent the irrecoverable in-pipe flow from being included in the cumulative effective in-pipe flow length when the in-pipe pressure hysteresis state is identified. It stops pushing the conductor forward based on the theoretical wire delivery amount of the current round and generates a conductor reverse unloading command and pressure position record.

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