Tension integrated device and tension control circuit

Abstract

The application discloses a tension integrated device and a tension control circuit, the tension control circuit comprises a tension acquisition module, an analog-digital conversion module, a main control module and an analog quantity module, the tension acquisition module is used for collecting the winding tension of a high-speed winding machine in real time and outputting a tension analog signal, the analog-digital conversion module is used for converting the tension analog signal into a tension digital signal, when the main control module receives the tension digital signal, the main control module is compared with a preset tension threshold value, if the preset tension threshold value is exceeded, a shutdown signal is output, and the analog quantity module is used for controlling the high-speed winding machine to stop when the shutdown signal is received. The application can realize real-time monitoring of the winding tension through the tension acquisition module, and can control the high-speed winding machine to stop in time when the winding tension is abnormal, so that problems, such as uneven winding, coil deformation or wire fracture, caused by too large or too small winding tension can be effectively avoided, the quality of high-speed winding products can be improved, and the high-speed winding machine can be prevented from being damaged due to excessive stress caused by abnormal winding tension.

Description

[Technical Field] This utility model relates to the field of tension control technology, and in particular to a tension integrated device and tension control circuit. [Background Technology] High-speed winding machines are widely used in the winding of coils for electronic components such as motors, transformers, and inductors. They are key equipment in the electronics manufacturing industry, and their winding efficiency and coil quality directly affect the performance of downstream products.

[0001] Existing high-speed winding machines mostly rely on manual monitoring to control winding tension. However, manual methods have slow response speed and poor dynamic performance, and cannot accurately respond to tension changes in real time. This can easily lead to uneven winding, coil deformation, or wire breakage, which seriously affects product quality and cannot meet the needs of high-efficiency production of high-speed winding machines. [Utility Model Content] To solve the above-mentioned technical problems, this utility model provides a tension integration device and a tension control circuit.

[0002] To achieve the above objectives, this utility model proposes a tension control circuit, comprising: Tension acquisition module, which is used to acquire the winding tension of the high-speed winding machine in real time and output a tension analog signal; An analog-to-digital converter module is provided, the input of which is connected to the output of the tension acquisition module. The analog-to-digital converter module is used to convert the tension analog signal into a tension digital signal. The main control module has its control input terminal connected to the output terminal of the analog-to-digital converter module. When the main control module receives the tension digital signal, it compares it with a preset tension threshold. If the tension exceeds the preset tension threshold, the main control module outputs a stop signal. An analog quantity module is provided, the input of which is connected to the control output of the main control module. The analog quantity module is used to control the high-speed winding machine to stop when it receives a stop signal.

[0003] By adopting the above technical solution, the main control module monitors the winding tension in real time through the tension acquisition module, and promptly controls the high-speed winding machine to stop when the winding tension is abnormal. This effectively avoids problems such as uneven winding, coil deformation, or wire breakage caused by excessive or insufficient winding tension, improves the quality of high-speed wound products, and prevents the high-speed winding machine from being damaged due to excessive stress caused by jamming caused by abnormal winding tension. Secondly, compared with the previous manual monitoring and control methods, it can significantly improve the response speed and dynamic performance of the control system.

[0004] The tension control circuit described above further includes: A power supply module, the input terminal of which is electrically connected to a power interface, is used to provide a stable operating voltage for the control circuit.

[0005] In the tension control circuit described above, the power supply module includes: A voltage regulator unit, the input terminal of which is electrically connected to the power interface, is used to convert the output voltage of the power interface into a stable 24V DC power. The first step-down unit has its input terminal connected to the output terminal of the voltage regulator unit. The first step-down unit is used to step down 24V DC to 12V DC. The second step-down unit has its input terminal connected to the output terminal of the first step-down unit. The second step-down unit is used to step down 12V DC to 5V DC. The third step-down unit has its input terminal connected to the output terminal of the first step-down unit, and is used to step down 12V DC to 3.3V DC.

[0006] As described above, in a tension control circuit, the tension acquisition module includes a tension sensor interface JP2, common mode inductors CL1, CL2, CL3, CL4, L4, L5, L6, and L7. The output terminal of the second step-down unit is connected to one end of the inductor L7, and the other end of the inductor L7 is connected to one end of the common mode inductor CL4. The other end of the common mode inductor CL4 is connected to the positive excitation voltage terminal of the tension sensor interface JP2, the negative excitation voltage terminal of the tension sensor interface JP2 is connected to one end of the common mode inductor CL1, and the other end of the common mode inductor CL1 is connected to one end of the inductor L4. The other end of the inductor L4 is grounded. The negative analog differential signal output terminal of the tension sensor interface JP2 is connected to one end of the common mode inductor CL2, the other end of the common mode inductor CL2 is connected to one end of the inductor L5, the other end of the inductor L5 is connected to the negative analog differential signal input terminal of the analog-to-digital converter module, the positive analog differential signal output terminal of the tension sensor interface JP2 is connected to one end of the common mode inductor CL3, the other end of the common mode inductor CL3 is connected to one end of the inductor L6, and the other end of the inductor L6 is connected to the positive analog differential signal input terminal of the analog-to-digital converter module.

[0007] As described above, in a tension control circuit, the analog-to-digital conversion module includes: An analog-to-digital converter (ADC) is provided, with its input terminal connected to the output terminal of the tension acquisition module and its output terminal connected to the control input terminal of the main control module. The ADC is used to convert the tension analog signal into a tension digital signal.

[0008] As described above, in a tension control circuit, the analog quantity module includes: A digital-to-analog converter (DAC) is provided, the input of which is connected to the control output of the main control module. The DAC is used to convert the stop signal into an analog control signal to control the high-speed winding machine to stop.

[0009] The tension control circuit described above further includes: The display module has its display signal terminal connected to the display signal terminal of the main control module, and the display module is used to display device parameters; A button adjustment module, wherein the adjustment end of the button adjustment module is connected to the adjustment end of the main control module, and the button adjustment module is used to adjust parameter settings; An IO expansion module is provided, wherein the output terminal of an external device is connected to the device input terminal of the IO expansion module, and the IO output terminal of the IO expansion module is connected to the IO input terminal of the main control module. The IO output terminal of the main control module is connected to the IO input terminal of the IO expansion module, and the device output terminal of the IO expansion module is connected to the input terminal of the external device.

[0010] To achieve the above objectives, this utility model also provides a tension integration device, including a housing, in which a tension sensor is provided. One end of the tension sensor is fixed on the housing, and the other end is connected to the winding wheel of a high-speed winding machine. The tension sensor is used to collect the winding tension of the high-speed winding machine in real time. The housing also contains a circuit board, on which the tension control circuit described above is engraved.

[0011] As described above, the tension integration device further includes a tension overload protection mechanism inside the housing. The tension overload protection mechanism includes an overload protection groove disposed inside the tension sensor and a limit adjustment mechanism disposed at the end where the tension sensor is connected to the winding wheel. The limit adjustment mechanism is used to limit the force range of the tension sensor.

[0012] As described above, in a tension integration device, there are two anti-overload grooves, which are arranged at the upper and lower ends of the middle rod inside the tension sensor to form a deformation space for the middle rod. The limit adjustment mechanism includes a limit block, and the limit block is provided with a limit screw for limiting the force range of the tension sensor.

[0013] Compared with the prior art, the tension integrated device and tension control circuit proposed in this utility model have the following beneficial effects: 1. The tension control circuit proposed in this utility model has a main control module that monitors the winding tension in real time through a tension acquisition module. When the winding tension is abnormal, it promptly controls the high-speed winding machine to stop, effectively avoiding problems such as uneven winding, coil deformation, or wire breakage caused by excessive or insufficient winding tension. This improves the quality of high-speed wound products and prevents the high-speed winding machine from being damaged due to excessive stress caused by jamming caused by abnormal winding tension. Secondly, compared with the previous manual monitoring and control methods, it can significantly improve the response speed and dynamic performance of the control system.

[0014] 2. The tension integrated device proposed in this utility model integrates various functional modules into the housing, which greatly reduces the space occupied by the device. When used in high-speed winding machines, it does not require additional space for the operation panel or electrical cabinet, greatly simplifying the installation and maintenance process.

[0015] 3. The tension sensor proposed in this utility model has a sampling frequency of 14.4KHz. Through high-frequency sampling, it can capture minute changes in winding tension in real time, and can collect more accurate tension, which helps to improve winding quality. In addition, the high sampling frequency enables the control circuit to respond quickly to changes in tension and adjust the operating status of the high-speed winding machine in a timely manner, avoiding problems such as wire breakage or uneven winding caused by abnormal tension. [Attached Image Description] To more clearly illustrate the technical solutions in the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0016] Figure 1 This is a block diagram illustrating the circuit principle structure of this utility model; Figure 2 This is a partial circuit diagram of the tension acquisition module of this utility model; Figure 3 This is a circuit schematic diagram of the analog-to-digital conversion module of this utility model; Figure 4 This is a circuit schematic diagram of the main control module of this utility model; Figure 5 This is a circuit schematic diagram of the analog quantity module of this utility model; Figure 6 This is a circuit diagram of the power module of this utility model; Figure 7 This is a circuit diagram of the second step-down unit of this utility model; Figure 8 This is a circuit schematic diagram of the communication module of this utility model; Figure 9This is a circuit diagram of the display module and button adjustment module of this utility model; Figure 10 This is a circuit schematic diagram of the IO expansion module of this utility model; Figure 11 This is a three-dimensional structural diagram of the tension integration device of this utility model; Figure 12 This is another three-dimensional structural diagram of the tension integration device of this utility model; Figure 13 for Figure 11 A schematic diagram of the decomposition process; Figure 14 for Figure 13 Schematic diagram of the installation structure of the tension sensor; Figure 15 This is a cross-sectional structural diagram of the tension integration device of this utility model.

Detailed Implementation Methods

[0017] Please refer to Figures 1 to 10 As shown in the illustration, this embodiment proposes a tension control circuit, including a tension acquisition module 100, an analog-to-digital converter module 200, a main control module 300, and an analog quantity module 400. The tension acquisition module 100 is used to acquire the winding tension of the high-speed winding machine in real time and output a tension analog signal. The input terminal of the analog-to-digital converter module 200 is connected to the output terminal of the tension acquisition module 100, and the analog-to-digital converter module 200 is used to convert the tension analog signal into a tension digital signal. The control input terminal of the main control module 300 is connected to the output terminal of the analog-to-digital converter module 200. When the main control module 300 receives the tension digital signal, it compares it with a preset tension threshold. If the tension exceeds the preset tension threshold, the main control module 300 outputs a stop signal. The input terminal of the analog quantity module 400 is connected to the control output terminal of the main control module 300, and the analog quantity module 400 is used to control the high-speed winding machine to stop when it receives the stop signal.

[0018] In this embodiment, the main control module monitors the winding tension in real time through the tension acquisition module, and promptly controls the high-speed winding machine to stop when the winding tension is abnormal. This effectively avoids problems such as uneven winding, coil deformation, or wire breakage caused by excessive or insufficient winding tension, thereby improving the quality of high-speed wound products and preventing damage to the high-speed winding machine due to excessive stress caused by jamming caused by abnormal winding tension. Secondly, compared with the previous manual monitoring and control methods, this significantly improves the response speed and dynamic performance of the control system.

[0019] It is worth noting that the aforementioned high-speed winding machines include, but are not limited to, high-speed copper wire winding machines for winding motor stator / transformer coils, high-speed fiber winding machines for winding optical cables / textile fibers, and high-speed winding machines for winding yarn / silk threads.

[0020] Furthermore, as a preferred embodiment of this solution and not a limitation, it also includes a power supply module 500, the input terminal of which is electrically connected to a power interface, and the power supply module 500 is used to provide a stable operating voltage for the control circuit.

[0021] In a preferred embodiment, the power module 500 includes a voltage regulator unit 510, a first buck unit 520, a second buck unit 530, and a third buck unit 540. The input terminal of the voltage regulator unit 510 is electrically connected to the power interface, and the voltage regulator unit 510 is used to convert the output voltage of the power interface into a stable 24V DC power. The input terminal of the first buck unit 520 is connected to the output terminal of the voltage regulator unit 510, and the first buck unit 520 is used to step down the 24V DC power to 12V DC power. The input terminal of the second buck unit 530 is connected to the output terminal of the first buck unit 520, and the second buck unit 530 is used to step down the 12V DC power to 5V DC power. The input terminal of the third buck unit 540 is connected to the output terminal of the first buck unit 520, and the third buck unit is used to step down the 12V DC power to 3.3V DC power.

[0022] Optionally, the voltage regulator unit 510 includes a diode D8, a thermistor PTC1, and a common-mode inductor RL1. The 24V output terminal (pin 2) of the power interface (JP4) is connected to one end of the thermistor PTC1, and the other end of the thermistor PTC1 is connected to the first input terminal (pin 1) of the common-mode inductor. The ground terminal (pin 1) of the power interface (JP4) is connected to the second input terminal (pin 4) of the common-mode inductor RL1. The first output terminal (pin 2) of the common-mode inductor RL1 is connected to the input terminal (VIN terminal) of the first buck unit 520, and the second output terminal (pin 3) of the common-mode inductor RL1 is grounded. A diode D8 is also connected between the ground terminal (pin 1) of the power interface (JP4) and the other end of the thermistor PTC1.

[0023] In this embodiment, the common-mode inductor RL1 can effectively filter out common-mode interference and other electromagnetic interference from the power interface, suppressing the impact of external interference signals on circuit performance. At the same time, the diode D8 provides polarity protection. When the polarity of the power interface is reversed, the diode D8 will reverse and cut off the power supply current, preventing the circuit from burning out due to reverse polarity of the power supply, thereby providing a stable and reliable operating voltage for subsequent circuits.

[0024] Optionally, the first step-down unit 520 includes a DC-DC converter U14, an inductor L3, a resistor FB2, and a Zener diode D7. The output terminal of the voltage regulator unit 510 is connected to the input terminal (i.e., VIN terminal) of the DC-DC converter U14, the output terminal (i.e., BOOT terminal) of the DC-DC converter U14 is connected to one end of the inductor L3, the other end of the inductor L3 is connected to one end of the resistor FB2, and the other end of the resistor FB2 outputs 12V DC. The output terminal (i.e., the BOOT terminal) of the DC-DC converter U14 is connected to the cathode of the Zener diode D7, and the anode of the Zener diode D7 is connected to the other end of the resistor FB2.

[0025] The DC-DC converter U14 is preferably model TPS54240.

[0026] In this embodiment, the 24V DC power is stably converted to 12V DC power by the DC-DC converter U14, providing a stable operating power supply for subsequent circuits and meeting the different power supply voltage requirements of different functional modules. Secondly, the 24V DC power is first stepped down to 12V DC power, and then the 12V DC power is stepped down to 5V DC power or 3.3V DC power. Compared with directly stepping down the 24V DC power to 5V DC power or 3.3V DC power, the step-down range is smaller, reducing power loss and improving power conversion efficiency.

[0027] Optionally, the second step-down unit 530 includes a linear regulator U6, the output terminal (i.e., VCC+12V) of the first step-down unit 520 is connected to the input terminal (i.e., IN terminal) of the linear regulator U6, and the output terminal (i.e., OUT terminal) of the linear regulator U6 outputs 5V DC power.

[0028] The preferred model of the linear regulator U6 is LT3042.

[0029] Optionally, the third step-down unit 540 includes a linear regulator U7, the output terminal (i.e., VCC+12V) of the first step-down unit 520 is connected to the input terminal (i.e., IN terminal) of the linear regulator U7, and the output terminal (i.e., OUT terminal) of the linear regulator U7 outputs 3.3V DC power.

[0030] The preferred model of the linear regulator U7 is L78M05.

[0031] In this embodiment, linear regulators U6 and U7 are used to step down the input 12V DC voltage to 5V DC voltage and 3.3V DC voltage in stages, providing a stable and suitable driving power for other subsequent circuit modules. Secondly, through the voltage regulation function of the linear regulators, the output DC voltage ripple is small and the stability is high, which can effectively suppress the impact of voltage fluctuations on other subsequent circuit modules and avoid errors such as inaccurate temperature acquisition caused by voltage fluctuations.

[0032] Furthermore, as a preferred embodiment of this solution and not a limitation thereof, the tension acquisition modulus 100 includes a tension sensor interface JP2, a common mode inductor CL1, a common mode inductor CL2, a common mode inductor CL3, a common mode inductor CL4, an inductor L4, an inductor L5, an inductor L6, and an inductor L7. The output terminal (i.e., AVCC+5V) of the second step-down unit 530 is connected to one end of the inductor L7, the other end of the inductor L7 is connected to one end of the common mode inductor CL4, the other end of the common mode inductor CL4 is connected to the excitation positive voltage terminal (i.e., E+ terminal) of the tension sensor interface JP2, the excitation negative voltage terminal (i.e., E- terminal) of the tension sensor interface JP2 is connected to one end of the common mode inductor CL1, the other end of the common mode inductor CL1 is connected to one end of the inductor L4, and the other end of the inductor L4 is grounded. The negative analog differential signal output terminal (S- terminal) of the tension sensor interface JP2 is connected to one end of the common mode inductor CL2, the other end of the common mode inductor CL2 is connected to one end of the inductor L5, the other end of the inductor L5 is connected to the negative analog differential signal input terminal (AIN- terminal) of the analog-to-digital converter module 200, the positive analog differential signal output terminal (S+ terminal) of the tension sensor JP2 is connected to one end of the common mode inductor CL3, the other end of the common mode inductor CL3 is connected to one end of the inductor L6, and the other end of the inductor L6 is connected to the positive analog differential signal input terminal (AIN+ terminal) of the analog-to-digital converter module 200.

[0033] Specifically, the output terminal of the second step-down unit 530 (i.e., AVCC+5V) provides a 5V excitation voltage to the excitation positive voltage terminal (i.e., E+ terminal) of the tension sensor interface JP2, enabling the tension sensor to work stably. When the high-speed winding machine is running, the tension sensor will deform under the force, thereby outputting an analog differential signal (i.e., tension analog signal) proportional to the winding tension through the analog differential signal positive output terminal (S+ terminal) and analog differential signal negative output terminal (S- terminal) of the tension sensor interface JP2. The analog-to-digital conversion module 200 then converts the received analog differential signal into a digital signal (i.e., tension digital signal).

[0034] In this embodiment, the filter unit composed of common-mode inductors CL1-CL4 and inductors L4-L7 can effectively suppress high-frequency electromagnetic interference generated during the high-speed operation of the high-speed winding machine, reduce the impact of power supply ripple and common-mode noise on the excitation voltage and tension acquisition of the tension sensor, and improve the acquisition accuracy of the tension acquisition signal.

[0035] Furthermore, as a preferred embodiment of this solution and not a limitation, the analog-to-digital conversion module 200 includes an analog-to-digital converter U16, the input terminal of which is connected to the output terminal of the tension acquisition module 100, and the output terminal of which is connected to the control input terminal of the main control module 300. The analog-to-digital converter is used to convert the tension analog signal into a tension digital signal.

[0036] The preferred model of the analog-to-digital converter U16 is AD7606.

[0037] For details, please see the appendix. Figure 3 As shown, the analog differential signal negative input terminal of the analog-to-digital converter U16 is connected to the analog differential signal negative output terminal of the tension acquisition module 100, the analog differential signal positive input terminal of the analog-to-digital converter U16 is connected to the analog differential signal negative output terminal of the tension acquisition module 100, and the output terminal (i.e., DOUT terminal) of the analog-to-digital converter U16 is connected to the control input terminal (i.e., SPI2_MISO terminal) of the main control module 300.

[0038] In this embodiment, the analog-to-digital converter U16 converts the acquired tension analog signal into a tension digital signal through its internal analog-to-digital conversion circuit. This reduces distortion and error in the transmission of the tension signal to the main control module, ensuring the integrity of the tension signal transmission. This helps the main control module to accurately control the winding tension, thereby enabling timely shutdown of the high-speed winding machine when abnormal winding tension occurs.

[0039] Furthermore, as a preferred embodiment of this solution and not a limitation, the main control module 300 includes a main control chip U4, and the main control chip U4 is preferably an STM32F103C8T6.

[0040] Furthermore, as a preferred embodiment of this solution and not a limitation, the analog module 400 includes a digital-to-analog converter U3. The input terminal (i.e., the SDIN terminal) of the digital-to-analog converter U3 is connected to the control output terminal (i.e., the 8760_DIN terminal) of the main control module 300. The digital-to-analog converter U3 is used to convert the stop signal into an analog control signal to control the high-speed winding machine to stop.

[0041] For details, please see the appendix. Figure 5 As shown, after the input terminal (i.e., SDIN terminal) of the digital-to-analog converter U3 receives the stop signal output from the control output terminal (i.e., 8760_DIN terminal) of the main control module 300, it will convert the stop signal into an analog control signal through the internal digital-to-analog conversion circuit, and then output the analog control signal to the high-speed winding machine through the input terminal (i.e., VIOUT terminal) of the digital-to-analog converter U3 to realize the stop control of the high-speed winding machine.

[0042] In this embodiment, the shutdown signal is converted into an analog control signal because analog signals can provide continuous and smooth changes, thereby gradually reducing the motor speed during the shutdown process of the high-speed winding machine, achieving smooth control of the high-speed winding machine, and avoiding sudden shutdown that could cause impact and damage to the equipment.

[0043] Furthermore, as a preferred embodiment of this solution and not a limitation, it also includes a display module 600, the display signal terminal of which is connected to the display signal terminal of the main control module 300, and the display module is used to display device parameters.

[0044] The equipment parameters mentioned therein include, but are not limited to, the current tension value, the target tension value, or the tension overload threshold.

[0045] In a preferred embodiment, the display module 600 includes a display driver unit 610 and a digital tube display unit 620. The display signal terminals (i.e., TM1640_MOSI and TM1640_CLK terminals) of the main control module 300 are connected to the display signal terminals of the display driver unit 610. The digit selection signal terminals (i.e., GR1, GR2, GR3, GR4, and GR5 terminals) of the display driver unit 610 are connected to the digit selection signal terminals of the digital tube display unit 620. The segment selection signal terminals (i.e., SEG1, SEG2, SEG3, SEG4, SEG5, SEG6, and SEG7 terminals) of the display driver unit 620 are connected to the segment selection signal terminals of the digital tube display unit 620.

[0046] Optionally, the display driving unit 610 includes a display driving chip U15, preferably a TM1640.

[0047] Alternatively, the digital tube display unit 620 may include a digital tube display SMG1, which is preferably a 5-digit digital tube display.

[0048] Specifically, the main control module 300 sends display data to the display driver chip U15 through its display signal terminals (i.e., TM1640_MOSI and TM1640_CLK terminals). Based on the received display data, the display driver chip U15 controls the digital tube display SMG1 to display the corresponding device parameters through the bit selection signal terminal and the segment selection signal terminal. For example, if the display data received by the display driver chip U15 is the current tension value of 250.0g, then the display driver chip U15 controls the digital tube display SMG1 to display "SET250.0g".

[0049] In this embodiment, the display module can intuitively display the equipment parameters of the high-speed winding machine, which makes it convenient for operators to monitor the operation of the high-speed winding machine in real time, and can also detect and deal with abnormalities in a timely manner.

[0050] Furthermore, as a preferred embodiment of this solution and not a limitation, it also includes a button adjustment module 700, the adjustment end of which is connected to the adjustment end of the main control module 300, and the button adjustment module 700 is used to adjust parameter settings.

[0051] The parameter settings include, but are not limited to, target tension value setting, tension overload threshold setting, and high-speed winding machine winding speed setting.

[0052] In a preferred embodiment, the button adjustment module 700 includes a first button SW1, a second button SW2, a third button SW3, and a fourth button SW4. The adjustment end (i.e., KEY1 end) of the first button SW1 is connected to the first adjustment end (i.e., KEY1 end) of the main control module, the adjustment end (i.e., KEY2 end) of the second button SW2 is connected to the second adjustment end (i.e., KEY2 end) of the main control module, the adjustment end (i.e., KEY3 end) of the third button SW3 is connected to the third adjustment end (i.e., KEY3 end) of the main control module, and the adjustment end (i.e., KEY4 end) of the fourth button SW4 is connected to the fourth adjustment end (i.e., KEY4 end) of the main control module. The grounding terminals of the first button SW1, the second button SW2, the third button SW3, and the fourth button SW4 are connected in series and grounded.

[0053] The first button SW1 is configured as the menu button, the second button SW2 is configured as the up switch button, the third button SW3 is configured as the down switch button, and the fourth button SW4 is configured as the back button.

[0054] In this embodiment, the button adjustment module provides operators with a simple and intuitive human-machine interaction method. Operators can switch menu options by pressing the first button SW1, select the parameter item to be set, and then adjust the specific parameters by pressing the second button SW2 and the third button SW3. After the adjustment is completed, press the fourth button SW4 to exit and save. The whole operation process is simple and easy to understand. Moreover, the button adjustment module also enables operators to adjust the parameter settings in real time when facing different winding requirements or equipment changes, so as to adapt to the actual production needs.

[0055] Furthermore, as a preferred embodiment of this solution and not a limitation, it also includes a communication module 800. The data communication terminal of the communication module 800 is connected to the communication terminal of the main control module 300, and the device communication terminal of the communication module 800 is connected to an external communication device. The communication module 800 is used to upload device parameters to the external communication device, and the communication module is also used to download parameter setting data of the external communication device to the main control module 300.

[0056] The external communication device can be a control system such as an MES system or a host computer, or a data acquisition terminal such as a touch screen or a tablet.

[0057] In a preferred embodiment, the communication module 800 includes a communication chip U10 and a common-mode inductor L8. The data communication terminals (i.e., USART1_RX terminal, 485_RE terminal, and USART1_TX terminal) of the communication chip U10 are connected to the communication terminal of the main control module 300. The device communication terminals (i.e., 485 / BT- terminal and 485 / A-T+ terminal) of the communication chip U10 are also connected to the external communication device via the common-mode inductor L8.

[0058] Optionally, the communication chip U10 is preferably an RS485 communication chip.

[0059] In this embodiment, for example, when the main control module needs to upload device parameter data to the MES system, the communication terminal of the main control module sends the upload data to the communication chip. After receiving the upload data, the data communication terminal of the communication chip uploads it to the MES system through its device communication terminal, thereby facilitating operators to trace quality problems and production status during the production of the high-speed winding machine. Similarly, operators can also download parameter settings to the main control module via the touchscreen to enable remote operation.

[0060] Furthermore, as a preferred embodiment of this solution and not a limitation, it also includes an IO expansion module 900, wherein the output terminal of the external device is connected to the device input terminal of the IO expansion module 900, and the IO output terminal of the IO expansion module 900 is connected to the IO input terminal of the main control module 300; The IO output terminal of the main control module 300 is connected to the IO input terminal of the IO expansion module 900, and the device output terminal of the IO expansion module 900 is connected to the input terminal of an external device.

[0061] In a preferred embodiment, the IO expansion module 900 includes at least one IO input unit 910 and at least one IO output unit 920. The output terminal of the external device is connected to the input terminal of the IO input unit 910, and the output terminal of the IO input unit 910 is connected to the IO input terminal of the main control module. The IO input unit 910 is used to send the request command of the external device to the main control module 300. The IO output terminal of the main control module 300 is connected to the input terminal of the IO output unit 920, and the output terminal of the IO output unit 920 is connected to the input terminal of the external device. The IO output unit 920 is used to send the control commands of the main control module 300 to the external device to control the external device to perform corresponding operations.

[0062] Optionally, the IO input unit 910 includes an optocoupler U13 and a resistor R33. The output terminal (i.e., IN1 terminal) of the external device is connected to one end of the resistor R33, the other end of the resistor R33 is connected to the anode terminal of the optocoupler U13, the cathode terminal of the optocoupler U13 is connected to the common output terminal (i.e., COM1 terminal) of the external device, the positive output terminal of the optocoupler U13 is connected to the IO input terminal (i.e., IO_IN1 terminal) of the main control module, and the negative output terminal of the optocoupler U13 is grounded.

[0063] Optionally, the IO output unit 920 includes an optocoupler U9, a switching transistor Q3, and a resistor R22. The output terminal (i.e., VCC_3.3V_CPU) of the third step-down unit 540 is connected to the anode of the optocoupler U9. The IO output terminal (i.e., IO_OUT1 terminal) of the main control module is connected to one end of the resistor R22, and the other end of the resistor R22 is connected to the cathode of the optocoupler U9. The positive output terminal of the optocoupler U9 is connected to the gate of the switching transistor Q3, and the negative output terminal of the optocoupler U9 is connected to the source of the switching transistor Q3. The drain of the switching transistor Q3 is connected to the input terminal (i.e., OUT1 terminal) of an external device.

[0064] The aforementioned external devices may include, but are not limited to, audible and visual alarms, solenoid valves, wound motors, and other equipment.

[0065] For example, in this embodiment, an audible and visual alarm is connected via an IO expansion module. When the main control module detects an overload of tension, the IO output terminal (i.e., IO_OUT1 terminal) of the main control module outputs an audible and visual alarm signal. When the optocoupler U9 receives the audible and visual alarm signal, the optocoupler U9 is turned on, thereby providing a drive current to the gate of the switching transistor Q3, causing the switching transistor Q3 to also be turned on. After the switching transistor Q3 is turned on, it outputs a drive signal to the audible and visual alarm, causing the audible and visual alarm to sound and light to alert the operator.

[0066] Please refer to Figures 11 to 15 As shown in the embodiment of this specification, a tension integrated device is also proposed, including a housing 1. A tension sensor 10 is provided inside the housing 1. One end of the tension sensor 10 is fixed on the housing 1, and the other end is connected to the winding wheel 2 of the high-speed winding machine. The tension sensor 10 is used to collect the winding tension of the high-speed winding machine in real time. A circuit board 20 is also provided inside the housing 1. The circuit board 20 is engraved with the tension control circuit as described above.

[0067] The sampling frequency of the tension sensor 10 is 14.4 kHz.

[0068] In this embodiment, the circuit board of the tension integration device is engraved with the aforementioned tension control circuit, which enables timely control of the high-speed winding machine to stop when abnormal winding tension occurs. This avoids problems such as uneven winding, coil deformation, or wire breakage caused by excessive or insufficient winding tension, thereby improving the quality of high-speed wound products and preventing damage to the high-speed winding machine due to excessive stress caused by abnormal winding tension. Secondly, the tension integration device integrates various functional modules into the housing, greatly reducing the space occupied by the device. This eliminates the need for additional space on the operation panel or electrical cabinet when using the high-speed winding machine, significantly simplifying the installation and maintenance process.

[0069] Furthermore, the sampling frequency of the tension sensor in this embodiment is 14.4KHz. Through high-frequency sampling, it is possible to capture minute changes in winding tension in real time, and to collect more accurate tension data, which helps to improve winding quality. In addition, the high sampling frequency enables the control circuit to respond quickly to changes in tension and adjust the operating status of the high-speed winding machine in a timely manner, avoiding problems such as wire breakage or uneven winding caused by abnormal tension.

[0070] Furthermore, as a preferred embodiment of this solution and not a limitation, the housing 1 is also provided with an anti-tension overload protection mechanism 30. The anti-tension overload protection mechanism 30 includes an anti-overload groove 31 disposed inside the tension sensor 10 and a limit adjustment mechanism 32 disposed on the end of the tension sensor 10 connected to the winding wheel. The limit adjustment mechanism 32 is used to limit the force range of the tension sensor 10.

[0071] In a preferred embodiment, the overload protection groove 31 is provided in two parts, and the two overload protection grooves 31 are disposed at the upper and lower ends of the intermediate rod 11 inside the tension sensor 10 to form a deformation space for the intermediate rod 11.

[0072] Specifically, during high-speed winding, the winding wire rotates rapidly on the winding wheel, generating an upward force on the tension sensor 10. This causes the tension sensor 10 to be subjected to tension generated during winding. If the winding tension is overloaded, it will pull the tension sensor 10 upward, causing it to deform. However, by setting overload protection grooves 31 at both ends of the internal intermediate rod 11, an elastic deformation space is provided for the internal intermediate rod 11 when the winding tension is overloaded, preventing the tension sensor 10 from being directly pulled upward and deformed.

[0073] In a preferred embodiment, the limit adjustment mechanism 32 includes a limit block 321, and the limit block 321 is provided with a limit screw 322 for limiting the force range of the tension sensor 10.

[0074] Specifically, by adjusting the position of the limit screw 322, the maximum force on the tension sensor 10 can be limited. When the tension sensor 10 deforms to the limit screw 322, it will be limited to further deformation, thus preventing overload and ensuring that the tension sensor 10 can operate within the normal working range, guaranteeing the continuous production capacity of the high-speed winding machine.

[0075] Furthermore, as a preferred embodiment of this solution and not a limitation thereof, the front of the housing 1 is provided with a power interface 40 for providing power and an IO expansion interface 41 for connecting to external devices.

[0076] Furthermore, as a preferred embodiment of this solution and not a limitation, the top of the housing 1 is provided with a display component 50 for displaying device parameters and a button component 51 for adjusting parameter settings.

[0077] It is worth noting that since the tension integrated device proposed in this specification includes all the technical solutions of all the above-mentioned tension control circuit embodiments and the technical effects achieved are exactly the same, other technical effects of the tension integrated device in this specification will not be described in detail here.

[0078] Those skilled in the art should also understand that the above description is one embodiment provided in conjunction with specific content, and does not imply that the specific implementation of this utility model is limited to these descriptions. Furthermore, due to differences in industry naming conventions, it is not limited to the above names or English names. Any methods or structures similar to or identical to those of this utility model, or any technical deductions or substitutions made based on the concept of this utility model, should be considered within the scope of protection of this utility model.

Claims

1. A tension control circuit, characterized in that, include: Tension acquisition module, which is used to acquire the winding tension of the high-speed winding machine in real time and output a tension analog signal; An analog-to-digital converter module is provided, the input of which is connected to the output of the tension acquisition module. The analog-to-digital converter module is used to convert the tension analog signal into a tension digital signal. The main control module has its control input terminal connected to the output terminal of the analog-to-digital converter module. When the main control module receives the tension digital signal, it compares it with a preset tension threshold. If the tension exceeds the preset tension threshold, the main control module outputs a stop signal. An analog quantity module is provided, the input of which is connected to the control output of the main control module. The analog quantity module is used to control the high-speed winding machine to stop when it receives a stop signal.

2. The tension control circuit according to claim 1, characterized in that, Also includes: A power supply module, the input terminal of which is electrically connected to a power interface, is used to provide a stable operating voltage for the control circuit.

3. The tension control circuit according to claim 2, characterized in that, The power module includes: A voltage regulator unit, the input terminal of which is electrically connected to the power interface, is used to convert the output voltage of the power interface into a stable 24V DC power. The first step-down unit has its input terminal connected to the output terminal of the voltage regulator unit. The first step-down unit is used to step down 24V DC to 12V DC. The second step-down unit has its input terminal connected to the output terminal of the first step-down unit. The second step-down unit is used to step down 12V DC to 5V DC. The third step-down unit has its input terminal connected to the output terminal of the first step-down unit, and is used to step down 12V DC to 3.3V DC.

4. A tension control circuit according to claim 3, characterized in that, The tension acquisition module includes a tension sensor interface JP2, common mode inductors CL1, CL2, CL3, CL4, L4, L5, L6, and L7. The output terminal of the second step-down unit is connected to one end of the inductor L7, and the other end of the inductor L7 is connected to one end of the common mode inductor CL4. The other end of the common mode inductor CL4 is connected to the positive excitation voltage terminal of the tension sensor interface JP2. The negative excitation voltage terminal of the tension sensor interface JP2 is connected to one end of the common mode inductor CL1, and the other end of the common mode inductor CL1 is connected to one end of the inductor L4. The other end of the inductor L4 is grounded. The negative analog differential signal output terminal of the tension sensor interface JP2 is connected to one end of the common mode inductor CL2, the other end of the common mode inductor CL2 is connected to one end of the inductor L5, the other end of the inductor L5 is connected to the negative analog differential signal input terminal of the analog-to-digital converter module, the positive analog differential signal output terminal of the tension sensor interface JP2 is connected to one end of the common mode inductor CL3, the other end of the common mode inductor CL3 is connected to one end of the inductor L6, and the other end of the inductor L6 is connected to the positive analog differential signal input terminal of the analog-to-digital converter module.

5. A tension control circuit according to claim 1, characterized in that, The analog-to-digital conversion module includes: An analog-to-digital converter (ADC) is provided, with its input terminal connected to the output terminal of the tension acquisition module and its output terminal connected to the control input terminal of the main control module. The ADC is used to convert the tension analog signal into a tension digital signal.

6. A tension control circuit according to claim 1, characterized in that, The analog quantity module includes: A digital-to-analog converter (DAC) is provided, the input of which is connected to the control output of the main control module. The DAC is used to convert the stop signal into an analog control signal to control the high-speed winding machine to stop.

7. A tension control circuit according to claim 1, characterized in that, Also includes: The display module has its display signal terminal connected to the display signal terminal of the main control module, and the display module is used to display device parameters; A button adjustment module, wherein the adjustment end of the button adjustment module is connected to the adjustment end of the main control module, and the button adjustment module is used to adjust parameter settings; The communication module has a data communication terminal that is connected to the communication terminal of the main control module, and a device communication terminal that is connected to an external communication device. The communication module is used to upload device parameters to the external communication device, and also to download parameter setting data from the external communication device to the main control module. An IO expansion module is provided, wherein the output terminal of an external device is connected to the device input terminal of the IO expansion module, and the IO output terminal of the IO expansion module is connected to the IO input terminal of the main control module. The IO output terminal of the main control module is connected to the IO input terminal of the IO expansion module, and the device output terminal of the IO expansion module is connected to the input terminal of the external device.

8. A tension integration device, characterized in that, The device includes a housing, within which a tension sensor is provided. One end of the tension sensor is fixed to the housing, and the other end is connected to the winding wheel of a high-speed winding machine. The tension sensor is used to collect the winding tension of the high-speed winding machine in real time. The housing also includes a circuit board, on which the tension control circuit as described in any one of claims 1-7 is engraved.

9. A tension integration device according to claim 8, characterized in that, The housing is also provided with a tension overload protection mechanism, which includes an overload protection groove inside the tension sensor and a limit adjustment mechanism on the end where the tension sensor is connected to the winding wheel. The limit adjustment mechanism is used to limit the force range of the tension sensor.

10. A tension integration device according to claim 9, characterized in that, The overload protection groove is provided in two places, and the two overload protection grooves are set at the upper and lower ends of the middle rod inside the tension sensor to form a deformation space for the middle rod. The limit adjustment mechanism includes a limit block, and the limit block is provided with a limit screw for limiting the force range of the tension sensor.

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