Enameled wire linkage alarm method based on data acquisition control system

Abstract

The present application relates to the field of wire and cable manufacturing and industrial automation control, in particular to a varnishing machine bare wire linkage alarm method based on a data acquisition control system, comprising: acquiring bare wire sensor level signals, wire speed values, unwinding tension, winding tension, and temperature of each temperature zone to form a current operating parameter set; determining a dynamic filtering time according to the wire speed value, the effective detection length of the sensor, and a safety factor, and generating a pre-alarm information if the duration exceeds the time; calculating an alarm decision value by weighting the pre-alarm duration, the tension fluctuation amplitude, and the temperature risk value, and outputting a final bare wire alarm result when the decision threshold is reached; thereby avoiding alarm misjudgment caused by single level signals affected by electromagnetic interference.

Description

Technical Field

[0001] This invention relates to the fields of wire and cable manufacturing and industrial automation control, specifically to a method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system. Background Technology

[0002] Currently, the detection and alarm control of bare wire abnormalities in enameling machine production lines are usually based on a single bare wire sensor signal or fixed threshold logic. When the production line is under different linear speeds, tension fluctuations, and temperature changes in the temperature zone, the existing methods are difficult to accurately determine the bare wire abnormalities. Furthermore, in the process of linkage speed reduction and process safety control after the alarm, false alarms, asynchronous speed reduction, and wire overheating or breakage are prone to occur, which reduces the stability of equipment operation and the reliability of fault handling. Summary of the Invention

[0003] The purpose of this invention is to provide a bare wire linkage alarm method for enameling machines based on a data acquisition and control system, addressing the following technical problems: Existing enameling machine alarm technologies have significant shortcomings in accurately determining bare wire anomalies under varying operating conditions and in implementing linkage speed reduction and safety control based on equipment status. There is an urgent need to propose an intelligent linkage alarm system that can more accurately handle the correlation between multi-dimensional parameters and anomaly determination, and dynamically optimize speed reduction strategies. The purpose of this invention can be achieved through the following technical solutions: The bare wire linkage alarm method for enameling machines based on data acquisition and control system includes: acquiring the bare wire sensor level signal, the line speed value calculated from the rotation speed of each drive shaft, the wire tension, the wire take-up tension and the temperature of each temperature zone to form the current operating parameter set; The dynamic filtering time is determined based on the linear velocity value, the effective detection length of the sensor, and the safety factor. When the duration of the bare wire sensor level signal in the preset bare wire indication state is greater than the dynamic filtering time, a pre-alarm message is generated. The alarm judgment value is obtained by weighting the duration of the pre-alarm message, the tension fluctuation amplitude, and the temperature risk value. When the alarm judgment value is greater than or equal to the pre-stored judgment threshold, the final bare wire alarm result is output. Based on the final bare wire alarm result, the preset main drive shaft is selected as the reference shaft, and the deceleration slope of each drive shaft is determined by combining the pre-stored inertia of each drive shaft, the inertia of the reference shaft, the reference tension and the current operating parameter set. The minimum safe speed is determined according to the temperature zone dwell time constraint. The larger of the preset minimum target linear speed and the minimum safe speed is taken as the speed command to be issued, and the linkage control strategy is generated. The linkage control strategy is converted into a timing control word array containing the target speed register value, acceleration / deceleration time register value, action delay value, and output relay status. The programmable logic controller execution unit executes the linkage actions of deceleration in the wire feeding and take-up areas, water seal control in the annealing area, and exhaust control in the oven.

[0004] Preferably, when collecting the current operating parameter set, the intelligent input / output unit deployed near the bare wire sensor collects the level signal of the bare wire sensor at a preset sampling period, and simultaneously reads the line speed value, wire release tension, wire take-up tension and temperature of each temperature zone converted from the rotation speed of each drive shaft, forming a current operating parameter set including timestamps.

[0005] Preferably, when generating pre-alarm information, the dynamic filtering time is determined based on the line velocity value, the effective detection length of the sensor, and the safety factor; when the duration of the bare wire sensor level signal continuously in the preset bare wire indication state exceeds the dynamic filtering time, the pre-alarm information is output.

[0006] Preferably, in the alarm determination process, the duration of the pre-alarm information is the length of time the pre-alarm information lasts, the tension fluctuation amplitude is the fluctuation of the wire release tension and the wire take-up tension, the temperature risk value is the deviation mapping value of the temperature of each temperature zone relative to the nominal temperature, and the weighting coefficient used in the weighted calculation is the calibration parameter pre-stored in the control system.

[0007] Preferably, when generating the linkage control strategy, the current operating parameter set at the trigger time of the final bare wire alarm result is latched, the pre-stored reference shaft inertia and reference tension are read, the deceleration slope corresponding to each transmission shaft is determined based on the pre-stored basic deceleration, and the temperature zone dwell time constraint is determined according to the pre-stored nominal dwell time of each temperature zone and the temperature correction coefficient corresponding to the deviation between the current temperature and the nominal temperature, and the minimum safe speed is determined.

[0008] Preferably, when performing linkage control, the linkage control strategy is converted into the timing control word array and written into the continuous register address area of ​​the programmable logic controller execution unit.

[0009] Preferably, the dynamic filtering time also considers the sampling period and communication delay compensation, and sets a minimum filtering lower limit and a maximum filtering upper limit to limit its amplitude. The sampling period and communication delay compensation, the minimum filtering lower limit and the maximum filtering upper limit are all calibration parameters pre-stored in the control system.

[0010] Preferably, the minimum safe speed is determined based on the remaining length and remaining safe dwell time of each temperature zone; wherein, the remaining safe dwell time of each temperature zone is determined by the difference between the current temperature and the nominal temperature, and the minimum safe speed of each temperature zone satisfies the ratio relationship between the remaining length of the corresponding temperature zone and the remaining safe dwell time of the corresponding temperature zone.

[0011] Preferably, after reading the timing control word array, the programmable logic controller execution unit sequentially executes the deceleration of the wire feeding area and the wire taking area at different slopes, the delayed shutdown of the water seal control in the annealing area, and the accelerated heat dissipation of the furnace exhaust control. After the speed returns to zero, it enters a locked state that prohibits restarting and records an alarm log.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. This method determines the dynamic filtering time by combining the linear velocity and performs a weighted calculation to determine the alarm based on the duration of the pre-alarm, the amplitude of tension fluctuation, and the temperature risk value. This method overcomes the false alarm problem that is easy to occur when the traditional method is based on a single sensor signal or a fixed threshold, and significantly improves the accuracy of bare wire anomaly determination and the stability of equipment operation under different working conditions. 2. This method combines parameters such as drive shaft inertia and reference tension to determine the deceleration slope, and determines the minimum safe speed based on the temperature zone dwell time constraint to generate a linkage control strategy. This effectively avoids secondary faults caused by asynchronous deceleration, prevents overheating caused by wire staying in the temperature zone, and enhances the reliability of linkage deceleration and process safety control after alarm. Attached Figure Description

[0013] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a flowchart illustrating the bare wire linkage alarm method for enameling machines based on a data acquisition and control system, as described in this application. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0015] like Figure 1 As shown, the bare wire linkage alarm method for enameling machines based on data acquisition and control systems includes: Step 1: Collect the bare wire sensor level signal, the line speed value calculated from the rotation speed of each drive shaft, the wire release tension, the wire take-up tension, and the temperature of each temperature zone to form the current operating parameter set; Step 2: Determine the dynamic filtering time based on the main drive shaft speed value in the linear velocity value, the pre-calibrated effective detection length of the sensor, and the preset safety factor. When the duration of the bare wire sensor level signal in the preset bare wire indication state is greater than the dynamic filtering time, generate a pre-alarm message. Step 3: Based on the duration of the pre-alarm information, the tension fluctuation amplitude calculated from the wire tension and the wire take-up tension, and the temperature risk value calculated from the temperature of each temperature zone, a weighted calculation is performed to obtain the alarm judgment value. When the alarm judgment value is greater than or equal to the pre-stored judgment threshold, the final bare wire alarm result is output. Step 4: Based on the final bare wire alarm result, select the preset main drive shaft as the reference shaft, and determine the deceleration slope of each drive shaft by combining the pre-stored inertia of each drive shaft, the inertia of the reference shaft, the reference tension and the current operating parameter set. Determine the minimum safe speed according to the temperature zone dwell time constraint, and take the larger of the preset minimum target linear speed and the minimum safe speed as the speed command to be issued to generate the linkage control strategy. Step 5: Convert the linkage control strategy into a timing control word array containing the target speed register value, the acceleration and deceleration time register value of the pay-off shaft, the acceleration and deceleration time register value of the take-up shaft, the action delay value, the output relay status, and the update flag bit. The programmable logic controller execution unit executes the linkage actions of deceleration in the pay-off and take-up areas, water seal control in the annealing area, and exhaust control in the oven.

[0016] In step 1, the level signal of the bare wire sensor is acquired by an intelligent input / output unit deployed near the bare wire sensor at a preset sampling period, and the linear speed value, wire release tension, wire take-up tension and temperature of each temperature zone are read synchronously from the linear speed of each drive shaft. This forms a set of current operating parameters including timestamps.

[0017] In step 2, the duration counting method is as follows: when the sampled value of the bare wire sensor level signal first enters the preset bare wire indication state, the start timestamp is recorded. In each subsequent cycle, if the state remains unchanged, the cumulative duration is obtained by subtracting the start timestamp from the current timestamp. When the cumulative duration exceeds the dynamic filtering time, a pre-alarm message is generated and written to the event queue. Once the bare wire sensor level signal returns to the non-bare wire indication state, the cumulative duration is cleared and the temporary count record that has not yet reached the dynamic filtering time is deleted.

[0018] In step 3, the duration of the pre-alarm information is the length of time the pre-alarm information lasts, the tension fluctuation amplitude is the fluctuation of the wire release tension and the wire take-up tension, the temperature risk value is the deviation mapping value of the temperature of each temperature zone relative to the nominal temperature, and the weighting coefficients used in the weighted calculation are the calibration parameters pre-stored in the control system.

[0019] The original sensor level signal is separated from the current operating speed, tension and temperature status of the device. Dynamic filtering and confidence weighting calculation of multi-dimensional status are performed through edge computing nodes to avoid false alarms caused by electromagnetic interference of a single level signal. The intelligent input / output unit deployed at the front end of the bare wire sensor continuously reads the sensor level signal at a preset high-frequency sampling period; at the same time, the system reads the rotation speed, wire tension, wire take-up tension and temperature data of each temperature zone from the drive shaft encoder, tension sensor and temperature controller through the bus; The rotational speed data is converted into a linear velocity value by multiplying it by the nominal circumference of the corresponding drive shaft traction wheel. The above multi-source heterogeneous data is aligned and timestamped in the edge computing node to construct the current operating parameter set. Within each sampling period, the system writes the current operating parameter set in a fixed order according to the fields: acquisition timestamp, bare wire sensor status, main drive shaft speed, wire tension, wire take-up tension, and temperature of each temperature zone. Among them, the tension and temperature values ​​are retained from the most recent valid period, which can be directly called when calculating the fluctuation in the next period. The edge computing node calculates the dynamic filtering time at the current speed based on the extracted current linear velocity value, the pre-calibrated effective detection length of the sensor, and the safety factor. When the duration of the bare wire indication level reported by the intelligent input / output unit exceeds the dynamic filtering time, the system determines that the level change is not an instantaneous interference signal, generates a pre-alarm message, and writes it into the event queue. The duration is counted as follows: when the sampled value of the bare wire sensor level signal first enters the preset bare wire indication state, the start timestamp is recorded. In each subsequent cycle, if the state remains unchanged, the cumulative duration is obtained by subtracting the start timestamp from the current timestamp. Once the bare wire sensor level signal returns to the non-bare wire indication state, the cumulative duration is cleared and the temporary count records that have not yet reached the dynamic filtering time are deleted. The edge computing node extracts the duration of the pre-alarm information as the pre-alarm duration, and simultaneously calculates the fluctuation of the current wire tension and take-up tension as the tension fluctuation amplitude, and calculates the deviation mapping value of the actual temperature of each temperature zone relative to the nominal temperature as the temperature risk value. The specific mapping rule is: calculate the difference between the current temperature and the nominal temperature to obtain the temperature deviation. If the temperature deviation is less than or equal to the preset normal fluctuation upper limit, it is determined that there is no overheating risk and the deviation mapping value is 0. If the temperature deviation is between the upper limit of normal fluctuation and the overheating critical value, the difference between the temperature deviation and the upper limit of normal fluctuation is divided by the difference between the overheating critical value and the upper limit of normal fluctuation to obtain a linear mapping value in the (0,1) interval; if the temperature deviation is greater than or equal to the overheating critical value, the deviation mapping value is directly taken as 1. The tension fluctuation amplitude adopts a dual-channel synthesis rule: calculate the absolute value of the difference between the current period's pay-off tension and the previous effective period's pay-off tension, and the absolute value of the difference between the current period's take-off tension and the previous effective period's take-off tension, and take the larger of the two as the tension fluctuation amplitude of the current period. When the previous effective cycle does not exist, the default tension fluctuation amplitude is 0. In the case of multiple temperature zones existing in parallel, the system first calculates the deviation mapping value of each temperature zone according to the aforementioned rules, and then takes the maximum value as the temperature risk value for alarm judgment, so as to ensure that when any temperature zone shows a significant overheating trend, it will not be masked by the homogenization of other low-risk temperature zones. The system performs extreme value normalization on the values ​​of the pre-alarm duration and tension fluctuation amplitude. The specific normalization conversion rule is as follows: subtract the preset empirical minimum value of the corresponding indicator from the current calculated value of the indicator, and then divide by the preset difference between the empirical maximum and minimum values ​​of the indicator. This uniformly maps the indicator values ​​of different physical dimensions to [the specified value]. Within the dimensionless interval; For those that have already undergone nonlinear mapping and are inherently dimensionless The temperature risk value of the feature is directly used as the normalization result in subsequent calculations; The corresponding weight coefficients pre-stored in the control system are called, and the sum of these three weights is strictly constrained to 1. The three normalized indicators are weighted and summed to obtain the alarm judgment value. If the normalization result is less than 0, it is counted as 0; if it is greater than 1, it is counted as 1. If the empirical maximum value is equal to the empirical minimum value, the normalization result of the corresponding indicator is directly set to 0. The judgment value is compared with a preset judgment threshold, which is calculated by extracting judgment values ​​from the historical normal operation sample pool and calculating their expected value. with standard deviation And according to the upper limit formula of normal distribution The calculation and calibration result shows that if the judgment value reaches or exceeds the judgment threshold, the final bare wire alarm result will be triggered and output. After confirming the alarm, the system calculates the deceleration slope and safe speed based on the equipment inertia and process constraints, and converts them into a timing control word array, which is then sent to the programmable logic controller execution unit for unified execution, completing the hierarchical flow from state determination to action execution; If the data from the temperature controller fails to be returned in time due to bus congestion during a certain sampling period, the system will automatically read the stable temperature record of the previous effective period of the temperature zone as the substitute value for the current period, and add a calculation mark to the data of the period, thereby avoiding the interruption of global weighted calculation due to the lack of single-point data; within the period in which the substitute value is used, the temperature zone still participates in the temperature risk value calculation according to the same deviation mapping rule, without switching the algorithm path separately; In one specific embodiment: On an enameling machine production line that includes multiple process areas such as wire feeding, annealing, painting, oven drying and wire taking, frequency converters and heaters are installed on site, resulting in continuous electromagnetic interference. When the wire passes through the bare wire sensor, if the sensor outputs an abnormal level pulse with a duration less than the preset pulse width threshold, the system calculates that the current line speed is greater than the set high speed threshold and the corresponding dynamic filtering time is less than the set short filtering time threshold. However, the pulse width is still less than the dynamic filtering time, so the system treats it as an interference pulse signal and discards it. If the abnormal level persists, the system generates a pre-alarm and takes into account the sudden change in the take-up tension and the deviation of the oven temperature. Only when the tension fluctuation and the duration of the level jointly push up the alarm judgment value and exceed the threshold will the system confirm that a real bare wire fault has occurred. In this embodiment, in step 4, the current operating parameter set at the time of triggering the final bare wire alarm result is latched, the pre-stored reference shaft inertia and reference tension are read, the deceleration slope corresponding to each transmission shaft is determined based on the pre-stored basic deceleration, and the temperature zone dwell time constraint is determined according to the pre-stored nominal dwell time of each temperature zone and the temperature correction coefficient corresponding to the deviation between the current temperature and the nominal temperature, and the minimum safe speed is determined.

[0020] In step 5, the linkage control strategy is converted into a timing control word array and written into the continuous register address area of ​​the programmable logic controller execution unit.

[0021] The dynamic filtering time also considers the sampling period and communication delay compensation, and sets a minimum filtering lower limit and a maximum filtering upper limit to limit its amplitude. The sampling period and communication delay compensation, the minimum filtering lower limit and the maximum filtering upper limit are all calibration parameters that are pre-stored in the control system.

[0022] The minimum safe speed is determined based on the remaining length and remaining safe dwell time of each temperature zone; the remaining safe dwell time of each temperature zone is determined by the difference between the current temperature and the nominal temperature, and the minimum safe speed of each temperature zone meets the following requirements. ,in, This represents the remaining length for the corresponding temperature range. This represents the remaining safe dwell time for the corresponding temperature zone.

[0023] After confirming the bare wire alarm, the system then calculates the differentiated deceleration slope and minimum safe speed limit based on the physical properties of each drive shaft and the current furnace temperature, to prevent wire breakage due to inertia mismatch during deceleration, or excessive heating of the wire in the oven due to excessive deceleration. At the data flow level, the system immediately triggers the state latching mechanism when it outputs the final bare wire alarm result, freezing the current set of operating parameters in a specific memory area; The edge computing node reads the inertia and reference tension of a pre-set reference axis, and combines this with the latched equivalent rotational inertia and current tension values ​​of each drive shaft. Based on the preset base deceleration, it calculates the independent deceleration slope of each drive shaft. The specific structured computation rules are as follows: according to the formula...

[0024] Calculate the dynamic filtering time, where the safety factor is... This indicates that the effective detection length of the sensor is... The current linear velocity is The preset non-zero minimum velocity constant is Sampling period compensation is Communication delay compensation is The minimum lower filter limit and the maximum upper filter limit are respectively and ,and Indicates when Less than Time to take ,when Greater than Time to take In other cases, take itself, Indicates taking and The larger of the two; The generation rule for the front-end filtering time has a uniquely determined input-output relationship, enabling the programmable logic controller or edge node to execute consistently. For the deceleration slope of each shaft after the alarm, the system uses the basic deceleration as a benchmark, calculates the inertia ratio coefficient based on the ratio of the current transmission shaft inertia to the reference shaft inertia, and constructs a tension compensation term using the deviation multiplier between the current tension and the reference tension. The deviation multiplier is obtained by multiplying the difference between the current tension and the reference tension by a preset tension adjustment gain constant. The tension adjustment gain constant is preset to the physical conversion unit of the ratio of acceleration to tension. The system is based on the formula

[0025] Calculate the first The speed reduction slope of the drive shaft, where the first... The axial deceleration slope is denoted as The basic deceleration is denoted as , No. Axial moment of inertia is denoted as The reference axis moment of inertia is denoted as The preset minimum inertia constant used to prevent the denominator from being zero is denoted as The tension adjustment gain constant is denoted as , No. The current tension of the shaft is denoted as The reference tension is denoted as Indicates taking and The larger of the two; If the calculated result is less than the preset minimum deceleration, the output will be based on that minimum deceleration; if it is greater than the maximum deceleration allowed by the driver, the output will be based on that maximum deceleration; when the moment of inertia of a certain axis is much greater than that of the reference axis, the system will amplify the base deceleration through a proportional coefficient to force it to brake urgently in order to follow the overall speed. When the current tension is too high, the deceleration is further corrected using the tension compensation term to prevent secondary failures such as wire bulging or breakage caused by inertia. For hot areas such as ovens, the system extracts the equivalent physical distance from the bare wire fault point to the exit of the corresponding temperature zone as the remaining length of each temperature zone. Based on the difference between the current temperature and the nominal temperature, the system subtracts the product of the difference and the temperature correction coefficient from the pre-stored nominal residence time of each temperature zone to calculate the remaining safe residence time of the wire in that temperature zone. The temperature correction factor is pre-set by the system as the ratio of time to temperature change, i.e., the physical conversion unit of seconds per degree Celsius; according to the association rules explicitly stated in the embodiment.

[0026] Edge computing nodes strictly define the remaining length of the corresponding temperature zone. Divide by remaining safe stay time Calculate the minimum safe speed for each temperature zone. For cases where multiple temperature zones coexist, the system calculates the minimum safe speed for each temperature zone and takes the maximum value as the minimum safe speed constraint for the entire line, so as to ensure that the speed of the entire line is not lower than the lower limit requirement of any temperature zone. The system then compares the minimum safe speed for the entire line with the preset minimum target linear speed, and takes the larger one as the final speed command issued. The generated deceleration slope, target speed command, and related auxiliary action timing are packaged into a unified linkage control strategy and decomposed by the control word conversion module into a timing control word array containing the target speed register value, acceleration / deceleration time register value, action delay value, and output relay status. The specific conversion mapping rule is as follows: divide the target speed command by the preset maximum allowable linear speed of the driver, multiply it by the maximum digital range value of the programmable logic controller speed register, and round it down to get the target speed register value. Calculate the difference between the current speed and the target speed of each axis, divide it by the corresponding deceleration slope to obtain the theoretical deceleration time of each axis, extract the maximum value as the uniform absolute deceleration time of the entire line, and multiply the absolute deceleration time by the reciprocal of the time base of the internal timer of the programmable logic controller to convert it into an integer acceleration / deceleration time register value. The water seal action delay value is obtained by subtracting the time advance calculated based on the current linear velocity from the preset water seal basic delay constant. If the calculated value is less than zero, it is truncated to zero. The conversion is achieved by multiplying the current linear velocity by the preset water seal time conversion coefficient, which is preset to the ratio of time to speed, i.e., the physical conversion unit of seconds squared per meter. Based on the opening and closing logic of the water seal control and exhaust control actions, the opening and closing state of the water seal control is fixedly mapped to the 0th bit of binary data, and the high-speed operation state of the exhaust control is mapped to the 1st bit of binary data. The two bits are concatenated and encapsulated into a 16-bit integer mask word through logic shift instructions and bitwise OR operations to generate the output relay state. The above parameters are aligned and combined according to the continuous address requirements of the programmable logic controller (PLC) communication protocol to generate a timing control word array; this array is directly written into the continuous register address area of ​​the PLC execution unit. The system uses a fixed sequence of writing the target speed register value, the pay-off spindle acceleration / deceleration time register value, the take-up spindle acceleration / deceleration time register value, the action delay value, the output relay status, and the update flag bit. The programmable logic controller parses the data in this order only, without guessing or rearranging the fields. When calculating the dynamic filtering time, the sampling period of the intelligent input / output unit and the bus communication delay are extracted as fixed time compensation terms and added to the preliminary calculation results to avoid the compression of the fault tolerance time caused by the inherent lag in communication. The pre-stored minimum filtering lower limit and maximum filtering upper limit are used to perform hard limiting processing on the superimposed value. The range of the upper and lower limits is obtained through the no-load anti-interference calibration of the field equipment to ensure the stability of the filtering window. In the calculation and deduction of safe speed and deceleration slope, if the current tension value of a certain shaft is abnormally zero due to the instantaneous disconnection of the sensor, the system will automatically call the preset minimum constant as the denominator compensation term to prevent the division by zero error during the calculation process from causing the interruption of the control strategy generation queue. In addition, when the current oven temperature is abnormally high, causing the calculated remaining safe dwell time to approach or equal to zero, the system will apply a preset non-zero minimum time constant to the remaining safe dwell time for hard limiting replacement. This prevents division by zero errors when calculating the minimum safe speed and avoids the generated minimum safe speed exceeding the speed command range allowed by the driver, thus triggering protection actions. In this case, the final speed lower limit is still generated by calculating the same temperature zone and taking the maximum value to form a full-line constraint, without switching control branches. In one specific embodiment: when the enameling machine production line confirms the bare wire alarm, the system identifies that the take-up shaft has a full reel of wire, and the difference between its rotational inertia and the rotational inertia of the pay-off shaft is greater than a preset inertia difference threshold. If the system stops freely in this state due to its inertia, the winding speed at the take-up end will be greater than the feeding speed at the feeding end because the inertia of the take-up shaft is greater than that of the feed-out shaft, which may lead to the risk of the wire breaking. Based on this, the system performs a deduction based on the latched parameters and calculation rules, and assigns a deceleration slope with an absolute value greater than the preset slope threshold to the main drive and take-up shaft. At the same time, it assigns a deceleration slope with an absolute value less than or equal to the preset slope threshold to the feed-out shaft, ensuring that the feeding speed in the feeding area is not lower than the winding speed in the take-up area during the deceleration period, and avoiding secondary failures of wire breakage due to sudden increase in tension. Meanwhile, the system detects that the current temperature inside the oven is higher than the nominal process temperature and the difference is within the preset fluctuation range. It calculates that the allowable residence time of the wire in the oven is less than the preset residence time threshold. If the speed of the entire line is directly reduced to the preset minimum operating speed threshold, the wire will stay in the oven for too long and overheat. Therefore, the system calculates the corresponding minimum safe speed and forces the target speed issued to the programmable logic controller to be maintained above the safe speed threshold, thereby achieving a balance between mechanical anti-breakage speed reduction and process thermal safety. During the process of implementing this overheat protection safety lower limit speed reduction, as the wire segment is continuously moved out of the oven, the remaining length of the corresponding temperature zone continues to decrease. At the same time, combined with the cooling effect of the exhaust heat dissipation action, the denominator of the remaining safe dwell time dynamically increases. The minimum safe speed command limit periodically recalculated by the system will also dynamically decrease and eventually drop to zero. This avoids the control conflict between maintaining speed to prevent overheating and stopping and locking alarm response in the control link. In this embodiment, after reading the timing control word array, the programmable logic controller execution unit sequentially executes the deceleration of the wire feeding area and the take-up area at different slopes, the delayed shutdown of the water seal control in the annealing area, and the accelerated heat dissipation of the furnace exhaust control. After the speed returns to zero, it enters a locked state that prohibits restarting and records the alarm log.

[0027] As a deterministic actuator, the programmable logic controller (PLC) strictly follows the preset timing control words to distribute actions. At the data flow level, the programmable logic controller execution unit continuously monitors the timing control word array update flag in the continuous register address area through a hardware cycle polling mechanism. Once the flag update is detected, the array content is read directly without any secondary logic deduction. Based on the acceleration / deceleration time register value read for the first time, the programmable logic controller (PLC) issues deceleration commands with different slopes to the frequency converters in the pay-off and take-up zones respectively. During the synchronization cycle of deceleration execution, the PLC parses the action delay value and the output relay status, and internally triggers the hardware timer corresponding to the action delay value. After the timer overflows, it forcibly flips the contact level of the output relay corresponding to the annealing zone water seal control solenoid valve, thereby executing the physical layer's delayed shutdown action. At the same time, the speed-up command is directly output to the control loop of the oven exhaust fan without delay to start the exhaust cooling. As the exhaust fan speeds up and the high-temperature wires are continuously moved out, the edge computing node periodically recalculates and continuously refreshes the target speed register value written to the continuous register area. The programmable logic controller dynamically receives and updates the speed command lower limit of the frequency converter driver by relying on the aforementioned hardware polling mechanism, so that the minimum safe speed constraint value is dynamically released in a time-progressive manner on the control link. When the target speed command received by the programmable logic controller (PLC) returns to zero and each drive shaft continues to decelerate smoothly under conflict-free commands until the encoder feedback speed returns to zero, the PLC updates its internal state machine, cuts off the enable signal of the main start circuit, enters a locked state that prohibits restarting, and writes the complete action sequence and status code of this execution into non-volatile memory to generate an alarm log. During the execution of the timing action, if the programmable logic controller detects that the frequency converter driver of a certain drive shaft has reported an offline or communication timeout status, the programmable logic controller will immediately bypass the smooth deceleration command of that shaft and directly trigger the hardware-level safety torque cancellation signal of the driver to stop it freely. At the same time, the ventilation and water seal linkage actions of other process areas will continue to be executed to prevent local communication failure from causing global process control failure. In one specific embodiment: after the enameling machine production line receives the timing control word, the wire feeding motor and the wire taking motor begin to decelerate smoothly at different deceleration rates; at this time, the water seal valve in the annealing zone does not immediately shut off, but continues to maintain the water seal for a period of time according to the delay setting in the control word, so as to prevent the high-temperature wire that has not been completely cooled from oxidizing rapidly in the air. At the same time, the exhaust fan speed of the oven increases to quickly extract the heat accumulated in the oven and prevent the wire from being overheated during the speed reduction period. Finally, as the speed command dynamically issued by the upper system drops to the zero limit, the entire transmission shaft stops smoothly and the lock status light on the equipment panel illuminates. At this time, even if the start button is pressed, the main control circuit of the system will not respond. The lock status can only be released after the on-site personnel confirm the bare wire fault and manually complete the reset command.

[0028] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system, characterized in that, include: Step 1: Collect the bare wire sensor level signal, the line speed value calculated from the rotation speed of each drive shaft, the wire release tension, the wire take-up tension, and the temperature of each temperature zone to form the current operating parameter set; Step 2: Determine the dynamic filtering time based on the main drive shaft speed value in the linear speed value, the pre-calibrated effective detection length of the sensor, and the preset safety factor. When the duration of the bare wire sensor level signal being in the preset bare wire indication state is greater than the dynamic filtering time, generate a pre-alarm message. Step 3: Based on the duration of the pre-alarm information, the tension fluctuation amplitude calculated from the wire tension and the wire take-up tension, and the temperature risk value calculated from the temperature of each temperature zone, a weighted calculation is performed to obtain the alarm judgment value. When the alarm judgment value is greater than or equal to the pre-stored judgment threshold, the final bare wire alarm result is output. Step 4: Based on the final bare wire alarm result, select the preset main drive shaft as the reference shaft, and determine the deceleration slope of each drive shaft by combining the pre-stored inertia of each drive shaft, the inertia of the reference shaft, the reference tension and the current operating parameter set. Determine the minimum safe speed according to the temperature zone dwell time constraint, and take the larger of the preset minimum target linear speed and the minimum safe speed as the speed command to be issued to generate the linkage control strategy. Step 5: Convert the linkage control strategy into a timing control word array containing the target speed register value, the acceleration and deceleration time register value of the pay-off shaft, the acceleration and deceleration time register value of the take-up shaft, the action delay value, the output relay status, and the update flag bit. The programmable logic controller execution unit executes the linkage actions of deceleration in the pay-off and take-up areas, water seal control in the annealing area, and exhaust control in the oven.

2. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 1, characterized in that, In step 1, the level signal of the bare wire sensor is acquired by an intelligent input / output unit deployed near the bare wire sensor at a preset sampling period, and the linear speed value, wire release tension, wire take-up tension and temperature of each temperature zone are read synchronously from the linear speed of each drive shaft. This forms a set of current operating parameters including timestamps.

3. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 1, characterized in that, In step 2, the counting method for the duration is as follows: when the sampled value of the bare wire sensor level signal first enters the preset bare wire indication state, the start timestamp is recorded. In each subsequent cycle, if the state remains unchanged, the cumulative duration is obtained by subtracting the start timestamp from the current timestamp. When the cumulative duration exceeds the dynamic filtering time, the pre-alarm information is generated and written into the event queue; once the bare wire sensor level signal returns to the non-bare wire indication state, the cumulative duration is cleared and the temporary count record that has not yet reached the dynamic filtering time is deleted.

4. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 1, characterized in that, In step 3, the duration of the pre-alarm information is the length of time the pre-alarm information lasts, the tension fluctuation amplitude is the fluctuation of the wire release tension and the wire take-up tension, the temperature risk value is the deviation mapping value of the temperature of each temperature zone relative to the nominal temperature, and the weighting coefficients used in the weighted calculation are calibration parameters pre-stored in the control system.

5. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 1, characterized in that, In step 4, the current operating parameter set at the time of triggering the final bare wire alarm result is latched, the pre-stored reference shaft inertia and reference tension are read, the deceleration slope corresponding to each transmission shaft is determined based on the pre-stored basic deceleration, and the temperature zone dwell time constraint is determined according to the pre-stored nominal dwell time of each temperature zone and the temperature correction coefficient corresponding to the deviation between the current temperature and the nominal temperature, and the minimum safe speed is determined.

6. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 1, characterized in that, In step 5, the linkage control strategy is converted into the timing control word array and written into the continuous register address area of ​​the programmable logic controller execution unit.

7. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 1, characterized in that, The dynamic filtering time also considers the sampling period and communication delay compensation, and sets a minimum filtering lower limit and a maximum filtering upper limit to limit its amplitude. The sampling period and communication delay compensation, the minimum filtering lower limit and the maximum filtering upper limit are all calibration parameters that are pre-stored in the control system.

8. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 5, characterized in that, The minimum safe speed is determined based on the remaining length and remaining safe dwell time of each temperature zone; wherein, the remaining safe dwell time of each temperature zone is determined by the difference between the current temperature and the nominal temperature, and the minimum safe speed of each temperature zone satisfies the following conditions: ,in, This represents the remaining length for the corresponding temperature range. This represents the remaining safe dwell time for the corresponding temperature zone.

9. The method for alarm linkage of bare wires in enameling machines based on a data acquisition and control system according to claim 1, characterized in that, After reading the timing control word array, the programmable logic controller execution unit sequentially executes the deceleration of the wire feeding and take-up areas at different slopes, the delayed shutdown of the water seal control in the annealing area, and the accelerated heat dissipation of the furnace exhaust control. After the speed returns to zero, it enters a locked state that prohibits restarting and records an alarm log.

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