Development and Application of an Intelligent Control System for Automatic Take-up of Semi-finished Steel Wire

Addressing the critical bottlenecks in the semi-finished steel wire single-strand winding process—where heavy reliance on manual labor for spool changing, threading, and inspection leads to frequent equipment downtime and hinders the implementation of the “one-operator-multiple-machines” model—this paper proposes a “low-cost, modular, and progressive” intelligent upgrade solution. Tailored to the investment constraints faced by small and medium-sized enterprises （SMEs）, the scheme adopts a non-intrusive technical retrofit strategy. It innovatively integrates a “6-axis robotic arm + rail” system to automate bobbin replacement, knotting, visual recognition, and online precision quality inspection, thereby completely eliminating manual operational limitations. Furthermore, the deployment of industrial edge gateways unifies heterogeneous protocols, connects MES data links, and integrates AGV-based flexible logistics. Empirical results demonstrate that this approach significantly reduces non-production downtime, substantially improves overall equipment efficiency, and successfully establishes an efficient “one-operator-multiple-machines” production paradigm. The study validates that this path effectively resolves the contradiction between low profit margins and high capital investment, offering a high-return, actionable practical model for numerous mid-tier production lines currently stuck in a “semi-automatic” state to break through dual bottlenecks in efficiency and quality, ultimately achieving a transformation toward intelligent manufacturing.