Closed-loop control double-wheel traction device based on feedback of tension sensor

Abstract

The utility model relates to the field of insulated cable processing equipment, and aims to solve the technical problem that a conductor is stretched and deformed due to unstable tension control of a small-diameter conductor cable in the prior art. The utility model provides a closed-loop control double-wheel traction device based on tension sensor feedback, which is characterized by further comprising a tension sensor guide wheel connected with a tension sensor. The tension sensor is used for detecting the tension of a cable on a tension sensor guide wheel in real time and transmitting a detected cable tension electric signal to the PLC, and the PLC is used for calculating by using a PID control algorithm and outputting a control signal to the motor for closed-loop control so as to realize the real-time adjustment of the tension of the cable towards the motor torque of a set value; and a certain deflection angle is kept between the slicing wheel and the traction wheel in the rotation direction by arranging the slicing wheel at the deflection angle, so that the horizontal displacement smooth transition is ensured when the cable is wound on the slicing wheel, and local stress concentration caused by a traditional fixed guide wheel is avoided.

Description

Technical Field

[0001] This utility model relates to the field of insulated cable processing equipment; specifically, it relates to a closed-loop control dual-wheel traction device based on tension sensor feedback. Background Technology

[0002] The dance wheel is a prior art device used to control cable tension in traditional cable production lines. For example, Chinese utility model patent CN220222987U, published on December 22, 2023, discloses such a "multi-purpose dance wheel for optical cable production" device. Figure 1 As shown, the dancing wheel A3, the cable displacement sensor A4, and the piston rod of the cylinder A6 are connected. Depending on the specifications of the optical cable, the required tension is adjusted on the industrial control computer A10. After setting the tension, the industrial control computer A10 communicates data to the PLC controller A9 via Ethernet. The PLC controller A9 outputs an analog signal to the proportional valve A8. The proportional valve A8 controls its valve angle and the air output based on the analog signal, thus providing a constant tension to the cylinder A6. The cylinder A6 controls the tension of the dancing wheel A3, adapting to optical cables with different tension requirements. However, when using the dancing wheel to control conductor tension, especially when applied to micro-conductors, it can easily lead to dimensional instability phenomena such as excessively high conductor tensile deformation rate. This directly causes excessive deviation in the conductor cross-sectional area, resulting in significant deterioration of the key parameters of the finished product. For example, in the physical foaming process of foam insulation using micro-conductors, existing production processes, when applied to micro-conductors with a diameter ≤0.4mm in the high-precision extrusion stage, can experience melt pressure fluctuations of up to ±1.5MPa, leading to a conductor tensile deformation rate exceeding 3% and directly causing conductor cross-sectional area deviations of over ±5%. This dimensional instability will cause degradation of key primary parameters such as characteristic impedance fluctuations (typically ±5Ω) and structural return loss deterioration (≥-30dB), ultimately resulting in a transmission error rate exceeding 10^-5. Furthermore, long-term use of the mechanical motion of a dance wheel for tension control can easily lead to wear and drift. Utility Model Content

[0003] The technical problem to be solved by this utility model is to overcome the problem of unstable tension control in small-diameter conductor cables, which leads to the conductor being stretched and deformed, and to provide a closed-loop control dual-wheel traction device based on tension sensor feedback to improve the product quality of such cables.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A closed-loop control dual-wheel traction device based on tension sensor feedback includes a frame, a gearbox mounted on the frame, an AC servo motor, and a traction wheel. The motor provides driving force to the traction wheel through the gearbox. The device also includes a tension sensor guide wheel connected to a tension sensor. The tension sensor is used to detect the cable tension on the tension sensor guide wheel in real time and transmit the detected cable tension electrical signal to a PLC controller. The PLC controller uses a PID control algorithm to calculate and output a control signal to the motor for closed-loop control, which is used to realize real-time adjustment of the motor torque to make the cable tension tend to a set value.

[0006] Furthermore, the sensor is a uniaxial strain tension sensor installed at the center of the tension sensor guide wheel.

[0007] Furthermore, the sensor detects the tension at the cable exit point on the tension sensor guide wheel in real time.

[0008] Furthermore, the device also includes a split wheel, which is composed of at least two independent guide wheels. The winding direction of the guide wheel is set at an angle α with the winding direction of the traction wheel. The calculation formula is tanα = split wheel spacing H ÷ split wheel cable bottom diameter D.

[0009] Preferably, the traction wheel is arranged parallel to the frame plane, and the segmented wheel guide wheel is provided with an angle α between it and the frame plane.

[0010] Preferably, the number of independent guide wheels constituting the segmented wheel is 2 to 5.

[0011] This utility model brings the following beneficial effects:

[0012] 1. By setting a tension sensor to directly detect the cable tension, the electrical signal is fed back to the AC servo motor in real time to adjust its torque, which constitutes the PID closed-loop control of tension. This reduces the intermediate links in the tension control of traditional dance wheels, effectively improves the control accuracy and saves processing costs, especially ensuring the stability of tensile deformation during the tension control processing of micro conductors.

[0013] 2. The segmenting wheel is set with an offset angle to keep the segmenting wheel and the traction wheel at a certain angle in the direction of rotation, ensuring a smooth transition of horizontal displacement when the cable is wound around the segmenting wheel, and avoiding local stress concentration caused by traditional fixed guide wheels. Attached Figure Description

[0014] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the present invention.

[0015] Figure 1 This is a schematic diagram of the overall structure of the existing dance wheel tension control technology;

[0016] Figure 1 A1, Cable feed wheel; A2, Support frame; A3, Dance wheel; A4, Cable displacement sensor; A5, Cable output wheel; A6, Cylinder; A7, First air intake pipe; A8, Proportional valve; A9, PLC controller; A10, Industrial computer; A11, Second air intake pipe.

[0017] Figure 2 This is a front view of a preferred embodiment of the present invention;

[0018] Figure 3 yes Figure 2 A schematic diagram of the AA cross-section of the embodiment shown;

[0019] Figure 4 yes Figure 2 A schematic cross-sectional view of the segmented wheel in the illustrated embodiment;

[0020] Figure 5 This is a flowchart of the PID closed-loop control system.

[0021] Explanation of reference numerals in the attached figures:

[0022] 1. Frame; 2. Traction wheel; 3. Segmentation wheel; 4. Electrical control box; 5. Control panel; 6. Tension sensing guide wheel; 7. AC servo motor; 3-1. Segmentation guide wheel; 3-2. Segmentation wheel shaft; 3-3. Segmentation wheel pressure block; 3-4. Segmentation wheel seat.

[0023] S1, Cable inlet; S2, Cable segmented winding; S3, Cable outlet. Detailed Implementation

[0024] This invention provides a closed-loop control dual-wheel traction device based on tension sensor feedback. (Refer to reference...) Figure 2 , Figure 3As shown, the frame 1 is a sturdy, lightweight frame mainly constructed of aluminum profiles, facilitating installation and debugging. The device includes a traction wheel 2, which can be connected to a precision planetary gear reducer via an end cover and shaft key or a shrink sleeve. An AC servo motor 7 provides driving force to the traction wheel 2 through the precision planetary gear reducer, which is mounted on the frame. To maintain precise and stable cable tension before the next process, the device also includes a tension sensing guide wheel 6 connected to a tension sensor. The tension sensor is a single-axis strain gauge tension sensor installed at the center of the tension sensor guide wheel 6, detecting the tension at the cable exit point. During operation, the cable is wound around the traction wheel 2 and pulled to the tension sensing guide wheel 6. Through the single-axis tension sensor, the cable tension is applied to the strain gauge of the tension sensor, causing slight deformation of the elastic body. The resistance of the strain gauge changes accordingly, and this change is converted into a linear voltage signal through a Wheatstone bridge circuit. An electrical signal proportional to the tension is output to the PLC controller. The PLC controller uses a PID control algorithm to calculate and output a control signal to the motor for closed-loop control. The specific control process is as follows: Figure 5 As shown, the AC servo motor and the single-axis strain tension sensor constitute a PID closed-loop control. The tension sensor directly detects the real-time tension of the cable, transmitting the electrical signal to the PLC controller for PID calculation. The output control signal adjusts the servo motor's output torque in real time. The servo motor speed and cable diameter affect the cable tension. The dynamic changes in cable tension are fed back to the tension sensor, which dynamically balances the cable tension, forming a closed-loop drive to ensure constant cable tension. This device, applied in the physical foaming process of micro-conductors for foam insulation, can effectively suppress tensile deformation caused by melt pressure fluctuations (±1.5MPa), reducing the conductor cross-sectional area deviation from the traditional ±5% to within ±1%.

[0025] The device also includes a splitting wheel 3 and a traction wheel 2 to pull the cable. The cable enters the device from S1, i.e., the cable inlet, passes through the splitting wheel 3 to achieve multi-layer winding, and then exits through the tension-sensing guide wheel 6 to enter the subsequent device. In this preferred embodiment, the splitting wheel consists of three guide wheels 3-1, which are then connected to the frame 1 via guide wheel shaft 3-2 and splitting wheel pressure block 3-3, mounted on a shaft seat 3-4; see also [reference needed]. Figure 2 , Figure 4 Combinations 3-1 to 3-4 form a splitting wheel. The function of the splitting wheel is to allow the cable to be wound separately on different guide wheels of the splitting wheel, stabilizing the route. The cable enters the next process after passing through the splitting wheel, which can avoid the local stress concentration caused by the traditional fixed guide wheel.

[0026] In this preferred embodiment, the segmented wheel consists of three independent ceramic-coated guide wheels, modularly assembled from the segmented wheel shaft 3-2 and the segmented wheel seat 3-4. The segmented wheel is angled to ensure smooth horizontal displacement during cable winding, avoiding localized stress concentration caused by traditional fixed guide wheels. The working principle is as follows: Figure 4 As shown, during cable winding, if the slitting wheel remains horizontal to the winding direction, each cable entering the next guide wheel requires a displacement perpendicular to the winding direction. This process is detrimental to cable control, posing a risk of friction and interference between the cable and the guide wheel surface. Therefore, we convert this displacement into the deflection angle of the slitting wheel, calculated using the formula tanα = slitting wheel spacing H ÷ slitting wheel cable base diameter D; α is the deflection angle formed by the slitting wheel base 3-4 and the frame mounting, and the reference plane is the frame plane, perpendicular to the ground. Figure 4 , Figure 3 It can be seen that the traction wheel 2 is set parallel to the frame plane, and the guide wheel 3-1 of the segmented wheel has an angle α with the frame plane. Therefore, the winding direction of the guide wheel 3-1 and the winding direction of the traction wheel 2 have an angle α. In actual use, different sizes of segmented wheels are set with different angles α.

[0027] In this preferred embodiment, the frame is made of lightweight aluminum alloy in one piece, which reduces the overall weight by 30% and improves the installation and debugging efficiency by 50% compared with traditional dance wheel tension control devices.

[0028] The embodiments described above are only used to illustrate the present utility model and are not intended to limit the present utility model. Any person skilled in the art can make various modifications, changes or substitutions without departing from the technical scope disclosed in the present utility model. Therefore, all equivalent and similar technical methods should be covered within the patent protection scope of the present utility model.

Claims

1. A closed-loop control dual-wheel traction device based on tension sensor feedback, comprising a frame, a reduction gearbox mounted on the frame, an AC servo motor, and a traction wheel, wherein the motor provides driving force to the traction wheel through the reduction gearbox; characterized in that: The device also includes a tension sensor guide wheel connected to a tension sensor. The tension sensor is used to detect the cable tension on the tension sensor guide wheel in real time and transmit the detected cable tension electrical signal to the PLC controller. The PLC controller uses a PID control algorithm to calculate and output a control signal to the motor for closed-loop control, which is used to realize the real-time adjustment of the motor torque to make the cable tension tend to the set value.

2. The closed-loop control dual-wheel traction device based on tension sensor feedback according to claim 1, characterized in that: The sensor is a uniaxial strain tension sensor installed at the center of the tension sensor guide wheel.

3. A closed-loop control dual-wheel traction device based on tension sensor feedback according to claim 2, characterized in that: The sensor detects the tension at the cable exit point on the tension sensor guide wheel in real time.

4. A closed-loop control dual-wheel traction device based on tension sensor feedback as described in claim 1, 2, or 3, characterized in that: The device also includes a split wheel, which is composed of at least two independent guide wheels. The winding direction of the guide wheel is set at an angle α with the winding direction of the traction wheel. The calculation formula is tanα = split wheel spacing H ÷ split wheel cable bottom diameter D.

5. A closed-loop control dual-wheel traction device based on tension sensor feedback according to claim 4, characterized in that: The traction wheel is set parallel to the frame plane, and the segmented wheel guide wheel is at an angle α to the frame plane.

6. A closed-loop control dual-wheel traction device based on tension sensor feedback as described in claim 4, characterized in that: The number of independent guide wheels that make up the segmented wheel is 2 to 5.

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