Aluminum box packaging automatic discharging metering method and metering system thereof

Abstract

The invention relates to an automatic blanking metering method and system for aluminum box packaging, and the method comprises the following steps: inputting a target packaging weight in a human-computer interface through an operator, and setting the target packaging weight of each aluminum box; the actual weight of the aluminum box is detected in real time through a weighing sensor, and the detected actual weight is transmitted to a PLC; the PLC calculates an error value according to the difference between the target weight and the actual weight; a PI D control algorithm is used for adjusting the blanking rate; the PLC controller dynamically adjusts the working state of the blanking equipment according to an adjusting signal output by a PI D control algorithm; in the discharging process, the PLC adjusts PI D control parameters in real time according to new feedback data; when the actual weight of the aluminum box reaches the target weight, the system automatically stops discharging; according to the scheme, real-time feedback and dynamic adjustment can be achieved in the discharging process, so that the packaging weight of the aluminum box is accurately controlled, and the problems that in the prior art, discharging precision is insufficient, the process is unstable, and manual intervention is too much are solved.

Description

Technical Field

[0001] The invention specifically relates to an automatic blanking metering method for aluminum box packaging and a metering system thereof. Background Art

[0002] With the continuous development of automated production, the aluminum box packaging industry has put forward higher requirements for the accuracy and efficiency of the packaging process. Especially in terms of blanking metering, accurate control of the packaging weight of each aluminum box has become a key factor in improving production efficiency and reducing costs. However, the traditional aluminum box packaging blanking system faces multiple technical challenges in practical applications, which are mainly reflected in the following aspects:

[0003] Traditional aluminum box packaging systems rely on manual adjustment or simple quantitative control, and it is often difficult to accurately control the actual weight of each aluminum box. Due to the diversity of materials and possible fluctuations in the production process (such as changes in material particle size, humidity, etc.), the weight error during the unloading process is often large. This error not only affects the quality of the packaging, but may also lead to material waste and increase production costs.

[0004] In many traditional automated feeding systems, the control system usually lacks sufficient flexibility and real-time adjustment capabilities. When the physical properties of the material change (such as humidity, density, particle size, etc.), the feeding rate is often difficult to automatically adjust to cope with these changes. This leads to instability in the feeding process, and may cause over-feeding or under-feeding, affecting the accuracy and efficiency of aluminum box packaging.

[0005] Many existing unloading systems require operators to make frequent adjustments and interventions during the production process. This not only increases the complexity of manual operations, but also easily leads to reduced packaging accuracy due to human errors. Especially during the production process, when the type of material changes or the production line is abnormal, the operator needs to adjust the system parameters in time. This need for manual intervention seriously affects the degree of production automation.

[0006] In traditional packaging metering systems, due to the inaccuracy of the feeding process, over-feeding often occurs. This not only causes the aluminum box packaging to be overweight, but also may cause material waste and increase production costs. At the same time, over-feeding may affect the quality of the final product, resulting in packaging that does not meet standard requirements and even requires repackaging, further increasing production costs and time. Summary of the invention

[0007] In order to overcome the deficiencies and shortcomings of the prior art, the present invention proposes an automated blanking and metering method for aluminum box packaging and a metering system thereof. The method can realize real-time feedback and dynamic adjustment during the blanking process, thereby accurately controlling the packaging weight of the aluminum box, solving the problems of insufficient blanking accuracy, unstable process and excessive manual intervention in the prior art, and has significant technical advantages and application prospects.

[0008] The primary purpose of the present invention is achieved through the following technical solutions:

[0009] An automatic material feeding and metering method for aluminum box packaging comprises the following steps:

[0010] The operator inputs the target packaging weight on the human-machine interface to set the target packaging weight for each aluminum box;

[0011] The weighing sensor is used to detect the actual weight of the aluminum box in real time, and the detected actual weight is transmitted to the PLC controller;

[0012] The PLC controller calculates the error value based on the difference between the target weight and the actual weight;

[0013] Based on the error value, a PID control algorithm is used to adjust the material feeding rate, and the output value of the PID control algorithm is an adjustment signal of the material feeding device to control the increase or decrease of the material feeding rate;

[0014] The PLC controller dynamically adjusts the working state of the unloading equipment according to the regulation signal output by the PID control algorithm to ensure that the actual weight of the aluminum box is as close to the target weight as possible;

[0015] During the unloading process, the weighing sensor continuously monitors the actual weight of the aluminum box, and the PLC controller adjusts the PID control parameters in real time according to the new feedback data;

[0016] When the actual weight of the aluminum box reaches the target weight and the error is within the preset tolerance range, the system automatically stops unloading and completes the aluminum box packaging.

[0017] Preferably, the method in which the PLC controller calculates the error value according to the difference between the target weight and the actual weight is:

[0018] e(t)=Wtarget-Wactual

[0019] Among them, e(t) is the error value at the current moment, Wtarget is the set target weight, and Wactual is the actual weight detected in real time by the weighing sensor.

[0020] Preferably, the method of adjusting the feeding rate using the PID control algorithm is:

[0021] Calculate the PID output:

[0022] Proportional term P(t) = Kp·e(t)

[0023] Integral Item

[0024] Differential term

[0025] By calculating the values ​​of these three items, the output of the PID controller is obtained:

[0026]

[0027] Where Kp is the proportional gain, which determines the immediate effect of the error, Ki is the integral gain, which determines the cumulative effect of past errors, Kd is the differential gain, which determines the rate of error change, and t is time;

[0028] The PID output u(t) adjusts the feeding rate according to the error value. If the error is positive, it means that the actual weight is lower than the target weight, and the PLC will increase the feeding rate; if the error is negative, it means that the actual weight exceeds the target, and the PLC will reduce the feeding rate.

[0029] Preferably, the method for optimizing the proportional gain, integral gain and differential gain of the PID controller is:

[0030] Set the integral gain Ki and the differential gain Kd to zero;

[0031] Gradually increase the proportional gain Kp until the system output shows continuous self-oscillation, and record the proportional gain value at this time as the critical gain Ku;

[0032] Measure the period of critical oscillation, that is, the oscillation period of the system output signal, and record this period as the critical period Pu;

[0033] The gain parameters of the PID controller are calculated based on the critical gain Ku and the critical period Pu, according to the following formula:

[0034] Proportional gain Kp = 0.6 × Ku

[0035] Integral gain Ki = 2 × Ku / Pu

[0036] Differential gain Kd = 0.125 × Ku × Pu

[0037] The calculated PID gain parameters are applied to the target control system.

[0038] As a preference, the method further comprises the following steps:

[0039] When the actual weight of the aluminum box exceeds the set error range, the system automatically triggers an alarm and stops unloading;

[0040] If the unloading equipment or sensor fails, the system will automatically detect and send out an alarm signal to prompt the operator to check.

[0041] Preferably, the unloading equipment comprises at least one control element, which is a frequency converter, a servo motor or a solenoid valve.

[0042] As a preferred method, the PLC controller dynamically adjusts the working state of the unloading equipment according to the adjustment signal output by the PID control algorithm:

[0043] Determine the current unloading equipment;

[0044] If the driving motor of the current unloading equipment is controlled by a frequency converter, the adjustment signal output by the PID controller is directly used as the input signal of the frequency converter to adjust the speed of the motor;

[0045] If the current unloading equipment uses a servo motor, the output value of the PID controller controls the speed or position of the servo motor. The servo driver adjusts the rotation speed or feed speed of the motor according to the signal output by the PID, thereby changing the unloading rate.

[0046] If the current unloading equipment uses a solenoid valve, the opening of the solenoid valve is adjusted through the PID output signal with analog value 0-10V or 4-20mA.

[0047] Another technical problem to be solved by the present invention is to provide an automatic unloading and metering system for aluminum box packaging, comprising:

[0048] Human-machine interface for the operator to input the target packaging weight and set the target packaging weight for each aluminum box;

[0049] The weighing sensor is used to detect the actual weight of the aluminum box in real time and transmit the detected actual weight signal to the PLC controller;

[0050] A PLC controller is used to receive actual weight data from a weighing sensor, calculate an error value between a target weight and an actual weight, and execute a PID control algorithm based on the error value to output a regulating signal to control a material unloading rate of the unloading device;

[0051] The unloading equipment dynamically adjusts the working state and changes the unloading rate according to the regulation signal output by the PLC controller, so that the actual weight of the aluminum box is close to the target weight;

[0052] During the unloading process, the weighing sensor continuously monitors the actual weight of the aluminum box, and the PLC controller adjusts the PID control parameters in real time according to the new feedback data; when the actual weight of the aluminum box reaches the target weight and the error value is within the predetermined tolerance range, the PLC controller automatically sends a signal to stop unloading and completes the aluminum box packaging.

[0053] Another technical problem to be solved by the present invention is to provide an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein when the processor executes the program, an automatic blanking and metering method for aluminum box packaging as described above is implemented.

[0054] Another technical problem to be solved by the present invention is to provide a computer-readable storage medium on which a computer program is stored, and when the program is executed by a processor, the automatic blanking and metering method for aluminum box packaging as described in any of the above is implemented.

[0055] Compared with the prior art, the present invention has the following advantages:

[0056] Traditional feeding systems usually rely on manual adjustment or simple quantitative control methods, which are prone to over- or under-feeding. This solution introduces a weighing sensor to detect the actual weight of the aluminum box in real time and compare it with the set target packaging weight to ensure that the weight of each aluminum box accurately meets the requirements, solving the problem of excessive weight error during feeding.

[0057] In the actual production process, the weight of the aluminum box may be affected by many factors (such as the humidity of the material, particle size, etc.), which make the feeding process unstable. This solution combines the PLC controller with the PID control algorithm to dynamically adjust the feeding rate according to the error value fed back in real time, thereby accurately controlling the feeding process and solving the problem of unstable feeding caused by changes in material properties.

[0058] During the unloading process, the system can continuously monitor the actual weight of the aluminum box and adjust the parameters of the PID control algorithm based on real-time feedback, ensuring that the system can adaptively adjust and maintain the accuracy of the unloading process under changing conditions. This real-time feedback and adjustment mechanism solves the technical problem of maintaining accuracy in a dynamic environment.

[0059] This method greatly reduces the need for manual intervention through automatic control and PID adjustment. The operator only needs to set the target weight in the initial stage and no longer needs to frequently adjust the working status of the unloading equipment, thereby simplifying the operating process, improving production efficiency and reducing human errors.

[0060] The system precisely controls the amount of material being fed, ensuring that the actual weight of each aluminum box is close to the target weight and that the error is within a predetermined tolerance range, thus avoiding waste of packaging materials and increased costs due to excessive feeding, thereby achieving higher resource utilization efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 The present invention is a flow chart of an automatic material unloading and metering method for aluminum box packaging. DETAILED DESCRIPTION

[0062] The specific implementation modes of the present invention are further described in detail to make the technical solutions of the present invention easier to understand and grasp.

[0063] Example

[0064] See also Figure 1 As shown, an automatic material feeding and metering method for aluminum box packaging includes the following steps:

[0065] The operator inputs the target packaging weight on the human-machine interface to set the target packaging weight for each aluminum box;

[0066] The weighing sensor is used to detect the actual weight of the aluminum box in real time, and the detected actual weight is transmitted to the PLC controller;

[0067] The PLC controller calculates the error value based on the difference between the target weight and the actual weight;

[0068] Based on the error value, a PID control algorithm is used to adjust the material feeding rate, and the output value of the PID control algorithm is an adjustment signal of the material feeding device to control the increase or decrease of the material feeding rate;

[0069] The PLC controller dynamically adjusts the working state of the unloading equipment according to the regulation signal output by the PID control algorithm to ensure that the actual weight of the aluminum box is as close to the target weight as possible;

[0070] During the unloading process, the weighing sensor continuously monitors the actual weight of the aluminum box, and the PLC controller adjusts the PID control parameters in real time according to the new feedback data;

[0071] When the actual weight of the aluminum box reaches the target weight and the error is within the preset tolerance range, the system automatically stops unloading and completes the aluminum box packaging.

[0072] By monitoring the actual weight of the aluminum box in real time and comparing it with the target weight, and using the PID control algorithm to dynamically adjust the feeding rate, the error in the feeding process can be significantly reduced. The PID controller adjusts the feeding rate according to the error between the actual weight and the target weight, ensuring that the packaging weight of each aluminum box is as accurate as possible, avoiding over-feeding or under-feeding.

[0073] This method relies on automated control systems (PLC controllers, weighing sensors, PID algorithms, etc.) to complete most operations, reducing the need for manual intervention. The operator only needs to set the target packaging weight in the system, and the rest of the process is automatically completed by the system, reducing the risk of human error and improving production stability and consistency.

[0074] The actual weight of the aluminum box is continuously monitored by a weighing sensor, and the feeding rate is adjusted in real time by a PLC controller to ensure the continuous stability of the feeding process. When the error between the actual weight and the target weight changes, the PID control algorithm will adjust the feeding rate in real time according to the new error value. This real-time feedback mechanism can cope with the impact of material changes (such as humidity, density, particle size, etc.) on the feeding process during the production process, ensuring that each aluminum box can reach the expected packaging weight, especially for the packaging of irregular products such as toys.

[0075] Since PID control can accurately control the feeding rate, over-feeding or material waste is avoided. Once the system detects that the actual weight is close to the target weight, it will automatically stop feeding, avoiding material waste caused by excessive feeding. This is of great significance for reducing production costs and improving material utilization; this method optimizes the feeding process through automated control and reduces unnecessary waiting and adjustment time. In actual production, the system can automatically adjust according to real-time data, reducing the time for manual inspection and adjustment, thereby improving overall production efficiency.

[0076] The method by which the PLC controller calculates the error value based on the difference between the target weight and the actual weight is:

[0077] e(t)=Wtarget-Wactual

[0078] Among them, e(t) is the error value at the current moment, Wtarget is the set target weight, and Wactual is the actual weight detected in real time by the weighing sensor.

[0079] The method of using PID control algorithm to adjust the feeding rate is:

[0080] Calculate the PID output:

[0081] Proportional term P(t) = Kp·e(t)

[0082] Integral Item

[0083] Differential term

[0084] By calculating the values ​​of these three items, the output of the PID controller is obtained:

[0085]

[0086] Where Kp is the proportional gain, which determines the immediate effect of the error, Ki is the integral gain, which determines the cumulative effect of past errors, Kd is the differential gain, which determines the rate of error change, and t is time;

[0087] The PID output u(t) adjusts the feeding rate according to the error value. If the error is positive, it means that the actual weight is lower than the target weight, and the PLC will increase the feeding rate; if the error is negative, it means that the actual weight exceeds the target, and the PLC will reduce the feeding rate.

[0088] The PID controller can adjust the feeding rate in real time according to the difference between the target weight and the actual weight (error value). The combination of proportional, integral and differential terms enables the system to respond to errors quickly and make corrections, while avoiding over-adjustment or oscillation, ensuring the stability and accuracy of the feeding process.

[0089] Since the PID controller can feedback the error in real time and adjust the output dynamically, the system can automatically adjust when the actual weight deviates from the target weight. The proportional term enables the system to respond to the error immediately, the integral term helps to eliminate the long-term accumulated error, and the differential term can identify the error change trend in advance to avoid over-adjustment. Therefore, the entire system can adapt to a variety of different operating conditions and material characteristics to ensure that the target weight is achieved quickly and accurately.

[0090] By precisely controlling the material feeding rate, the material waste caused by over-feeding is reduced, thus effectively reducing production costs. At the same time, precise weight control also improves production efficiency, because each feeding can be closer to the target weight, avoiding frequent shutdowns and adjustments, and improving the overall efficiency of the production line.

[0091] The method for optimizing the proportional gain, integral gain and differential gain of the PID controller is:

[0092] Set the integral gain Ki and the differential gain Kd to zero;

[0093] Gradually increase the proportional gain Kp until the system output shows continuous self-oscillation, and record the proportional gain value at this time as the critical gain Ku;

[0094] Measure the period of critical oscillation, that is, the oscillation period of the system output signal, and record this period as the critical period Pu;

[0095] The gain parameters of the PID controller are calculated based on the critical gain Ku and the critical period Pu, according to the following formula:

[0096] Proportional gain Kp = 0.6 × Ku

[0097] Integral gain Ki = 2 × Ku / Pu

[0098] Differential gain Kd = 0.125 × Ku × Pu

[0099] The calculated PID gain parameters are applied to the target control system.

[0100] By gradually increasing the proportional gain Kp until the system shows continuous self-oscillation, the critical gain Ku and critical period Pu of the system can be directly obtained. This process does not require complex mathematical modeling or assumptions and is applicable to a variety of control systems. Therefore, it is a fast and easy-to-implement optimization method.

[0101] By optimizing the proportional gain, integral gain and differential gain, the response speed and stability of the control system can be balanced. The proportional gain Kp determines the immediate response of the system, the integral gain Ki can eliminate the long-term steady-state error of the system, and the differential gain Kd helps to reduce the overshoot and oscillation of the system. The gain parameters calculated based on the critical gain Ku and the critical period Pu can ensure that the system finds a good balance between response speed and stability, avoiding oscillation caused by too fast response or lag caused by too slow response.

[0102] This method adjusts the PID parameters based on the actual dynamic characteristics of the system, rather than blindly trying multiple experiments or over-adjusting. Through the critical gain method, over-adjustment and over-optimization can be avoided, ensuring that the selection of parameters meets the actual needs of the system, thereby avoiding unnecessary oscillations or instability in the system; the optimized PID parameters can enable the system to have stronger automatic adjustment capabilities when facing external disturbances or changes in system characteristics. On the basis of ensuring system stability, the critical gain method improves control accuracy and adaptability, and effectively reduces the need for human intervention and adjustment.

[0103] Since the PID controller can more accurately control the dynamic response of the system under the optimized parameter configuration, the overall stability of the system is improved, and problems such as material waste, over-adjustment, and response delay in the production process are alleviated. This optimization solution can help companies reduce production costs, improve production efficiency, and improve product quality.

[0104] The following steps are also included:

[0105] When the actual weight of the aluminum box exceeds the set error range, the system automatically triggers an alarm and stops unloading;

[0106] If the unloading equipment or sensor fails, the system will automatically detect and send out an alarm signal to prompt the operator to check.

[0107] The unloading equipment includes at least one control element, which is a frequency converter, a servo motor or a solenoid valve.

[0108] When the actual weight of the aluminum box exceeds the set error range, the system can automatically trigger an alarm and stop unloading, which can effectively prevent production problems caused by overweight or underweight, such as material waste, substandard quality, or subsequent processes not being able to proceed smoothly. Through this automatic feedback mechanism, the system can ensure that the production process is always under control, avoiding human operational errors or emergencies that affect production efficiency and product quality.

[0109] The system can automatically detect and send out an alarm signal when the unloading equipment or sensor fails, prompting the operator to check in time. This not only improves the reliability of the equipment, but also reduces the downtime and maintenance costs caused by equipment failure. The automatic fault diagnosis and alarm function allows the operator to locate the problem in the first time, repair or replace it, avoid unexpected pauses in the production process, and maximize the normal operation time of the equipment.

[0110] The system can automatically detect and respond to actual weight deviations and equipment failures, reducing the need for manual intervention and improving the level of automation. Automated control can reduce the workload of operators and the incidence of human errors, thereby improving the accuracy and efficiency of the production process. The introduction of automated fault detection and alarms further improves the operational efficiency and intelligence level of the factory.

[0111] The method by which the PLC controller dynamically adjusts the working state of the unloading equipment according to the regulation signal output by the PID control algorithm is:

[0112] Determine the current unloading equipment;

[0113] If the driving motor of the current unloading equipment is controlled by a frequency converter, the adjustment signal output by the PID controller is directly used as the input signal of the frequency converter to adjust the speed of the motor;

[0114] If the current unloading equipment uses a servo motor, the output value of the PID controller controls the speed or position of the servo motor. The servo driver adjusts the rotation speed or feed speed of the motor according to the signal output by the PID, thereby changing the unloading rate.

[0115] If the current unloading equipment uses a solenoid valve, the opening of the solenoid valve is adjusted through the PID output signal with analog value 0-10V or 4-20mA.

[0116] The PID control algorithm can dynamically adjust the output signal according to the error between the set target value and the actual measured value, making the feeding process more accurate. During the production process, whether it is controlling the motor speed, servo motor speed / position, or adjusting the opening of the solenoid valve, the PID controller can continuously adjust according to real-time feedback to maintain system stability; the PID controller can effectively reduce fluctuations caused by external disturbances, load changes, etc. through feedback adjustment, ensuring that the feeding rate is always in an optimal and stable state.

[0117] The solution designs control methods for unloading equipment with different drive modes (inverter, servo motor, solenoid valve), which improves the flexibility and adaptability of the system. According to the characteristics of different equipment, the output signal of the PID controller can automatically adapt to optimize the unloading control method:

[0118] Inverter control: The inverter can directly affect the feeding rate by adjusting the motor speed. The PID output signal controls the change of the motor speed so that the feeding amount is kept within the predetermined range at any time.

[0119] Servo motor control: Servo motors can precisely control the movement of materials during feeding by adjusting position, speed and acceleration. The output signal of the PID controller can adjust the operating state of the servo motor to achieve very precise feeding or position control.

[0120] Solenoid valve control: Solenoid valve control mainly adjusts the flow or pressure by adjusting the opening of the valve. The PID controller outputs an analog signal (such as 0-10V or 4-20mA) to control the opening of the solenoid valve, thereby accurately adjusting the material flow.

[0121] By integrating the PID control algorithm, the solution enables the system to automatically identify and adjust different types of unloading equipment without configuring a separate control strategy for each device. This universal control method reduces the complexity of system design and reduces hardware requirements; compared with traditional control methods, this solution reduces maintenance costs and energy consumption by adjusting the working status and control accuracy of the equipment. For example, the motor speed adjustment controlled by the inverter can save electricity without adding additional burden, and the precise control of the servo motor can reduce material waste.

[0122] By combining PID control algorithms and equipment adaptive adjustment, the system can achieve fully automatic material feeding control without manual intervention. Especially in complex production environments, automated PID adjustment can greatly improve production efficiency and reduce human operating errors and mistakes, thereby ensuring efficient, stable and consistent production processes; the automatic detection and adjustment mechanism can be adjusted at any time and automatically adapt to production changes, further improving the flexibility and response speed of the production line.

[0123] Accurate material feeding control directly affects the quality of the product. In the process of accurately adjusting the material feeding rate and flow rate, the PID control algorithm can effectively avoid over- or under-feeding, ensuring that the weight, volume and other quality indicators of each product meet the requirements. This control method helps to improve the consistency of the final product, reduce the defective product rate and improve production efficiency.

[0124] This solution combines the adjustment function of the PID controller, which can automatically correct the deviation by adjusting the output signal in time when the production status does not meet the expectations. The PID controller can also issue an alarm when the system is abnormal, prompting the operator to check and maintain. This not only improves the self-regulation ability of the system, but also enhances the fault diagnosis and prevention capabilities of the system; the adaptive characteristics of the PID control algorithm enable it to automatically adjust parameters when the equipment operating status changes (such as load changes, equipment wear, etc.), optimize the control effect, and ensure the stability of the production process.

[0125] An automatic unloading and metering system for aluminum box packaging, comprising:

[0126] Human-machine interface for the operator to input the target packaging weight and set the target packaging weight for each aluminum box;

[0127] The weighing sensor is used to detect the actual weight of the aluminum box in real time and transmit the detected actual weight signal to the PLC controller;

[0128] A PLC controller is used to receive actual weight data from a weighing sensor, calculate an error value between a target weight and an actual weight, and execute a PID control algorithm based on the error value to output a regulating signal to control a material unloading rate of the unloading device;

[0129] The unloading equipment dynamically adjusts the working state and changes the unloading rate according to the regulation signal output by the PLC controller, so that the actual weight of the aluminum box is close to the target weight;

[0130] During the unloading process, the weighing sensor continuously monitors the actual weight of the aluminum box, and the PLC controller adjusts the PID control parameters in real time according to the new feedback data; when the actual weight of the aluminum box reaches the target weight and the error value is within the predetermined tolerance range, the PLC controller automatically sends a signal to stop unloading and completes the aluminum box packaging.

[0131] This embodiment also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor implements the above-mentioned method for automatic blanking and metering of aluminum box packaging when executing the program.

[0132] This embodiment also provides a computer-readable storage medium on which a computer program is stored. When the program is executed by a processor, the automatic blanking and metering method for aluminum box packaging as described above is implemented.

[0133] Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiment methods can be completed by instructing the relevant hardware through a computer program, and the computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to memory, storage, database or other media used in the embodiments provided in this application can include non-volatile and / or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. As an illustration and not limitation, RAM is available in many forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link (Synchlink) DRAM (SLDRAM), memory bus (Rambus) direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM).

[0134] Those skilled in the art will clearly understand that for the sake of convenience and brevity of description, only the division of the above-mentioned functional units and modules is used as an example. In actual applications, the above-mentioned functions can be distributed and completed by different functional units and modules as needed, that is, the internal structure of the system can be divided into different functional units or modules to complete all or part of the functions described above.

[0135] Of course, the above are only typical examples of the present invention. In addition to these, the present invention may also have many other specific implementations. Any technical solutions formed by equivalent replacement or equivalent transformation fall within the scope of protection required by the present invention. Of course, the above are only typical examples of the present invention. In addition to these, the present invention may also have many other specific implementations. Any technical solutions formed by equivalent replacement or equivalent transformation fall within the scope of protection required by the present invention.

Claims

1. An automatic material feeding and metering method for aluminum box packaging, characterized in that , including the following steps: The operator inputs the target packaging weight on the human-machine interface to set the target packaging weight for each aluminum box; The weighing sensor is used to detect the actual weight of the aluminum box in real time, and the detected actual weight is transmitted to the PLC controller; The PLC controller calculates the error value based on the difference between the target weight and the actual weight; Based on the error value, a PID control algorithm is used to adjust the material feeding rate, and the output value of the PID control algorithm is an adjustment signal of the material feeding device to control the increase or decrease of the material feeding rate; The PLC controller dynamically adjusts the working state of the unloading equipment according to the regulation signal output by the PID control algorithm to ensure that the actual weight of the aluminum box is as close to the target weight as possible; During the unloading process, the weighing sensor continuously monitors the actual weight of the aluminum box, and the PLC controller adjusts the PID control parameters in real time according to the new feedback data; When the actual weight of the aluminum box reaches the target weight and the error is within the preset tolerance range, the system automatically stops unloading and completes the aluminum box packaging.

2. The automatic blanking and metering method for aluminum box packaging according to claim 1 is characterized in that: The method by which the PLC controller calculates the error value based on the difference between the target weight and the actual weight is: e(t)=Wtarget-Wactual Among them, e(t) is the error value at the current moment, Wtarget is the set target weight, and Wactual is the actual weight detected in real time by the weighing sensor.

3. The automatic blanking and metering method for aluminum box packaging according to claim 1 is characterized in that: The method of using PID control algorithm to adjust the feeding rate is: Calculate the PID output: Proportional term P(t) = Kp·e(t) Integral Item Differential term By calculating the values ​​of these three items, the output of the PID controller is obtained: Where Kp is the proportional gain, which determines the immediate effect of the error, Ki is the integral gain, which determines the cumulative effect of past errors, Kd is the differential gain, which determines the rate of error change, and t is time; The PID output u(t) adjusts the feeding rate according to the error value. If the error is positive, it means that the actual weight is lower than the target weight, and the PLC will increase the feeding rate; if the error is negative, it means that the actual weight exceeds the target, and the PLC will reduce the feeding rate.

4. The automatic blanking and metering method for aluminum box packaging according to claim 3 is characterized in that: The method for optimizing the proportional gain, integral gain and differential gain of the PID controller is: Set the integral gain Ki and the differential gain Kd to zero; Gradually increase the proportional gain Kp until the system output shows continuous self-oscillation, and record the proportional gain value at this time as the critical gain Ku; Measure the period of critical oscillation, that is, the oscillation period of the system output signal, and record this period as the critical period Pu; The gain parameter of the PID controller is calculated based on the critical gain Ku and the critical period Pu, according to the following formula: Proportional gain Kp = 0.6 × Ku Integral gain Ki = 2 × Ku / Pu Differential gain Kd = 0.125 × Ku × Pu The calculated PID gain parameters are applied to the target control system.

5. The automatic blanking and metering method for aluminum box packaging according to any one of claims 1 to 4, characterized in that: The following steps are also included: When the actual weight of the aluminum box exceeds the set error range, the system automatically triggers an alarm and stops unloading; If the unloading equipment or sensor fails, the system will automatically detect and send out an alarm signal to prompt the operator to check.

6. The automatic blanking and metering method for aluminum box packaging according to claim 5 is characterized in that: The unloading equipment includes at least one control element, which is a frequency converter, a servo motor or a solenoid valve.

7. The automatic blanking and metering method for aluminum box packaging according to claim 6 is characterized in that: The method by which the PLC controller dynamically adjusts the working state of the unloading equipment according to the regulation signal output by the PID control algorithm is: Determine the current unloading equipment; If the driving motor of the current unloading equipment is controlled by a frequency converter, the adjustment signal output by the PID controller is directly used as the input signal of the frequency converter to adjust the speed of the motor; If the current unloading equipment uses a servo motor, the output value of the PID controller controls the speed or position of the servo motor. The servo driver adjusts the rotation speed or feed speed of the motor according to the signal output by the PID, thereby changing the unloading rate. If the current unloading equipment uses a solenoid valve, the opening of the solenoid valve is adjusted through the PID output signal with analog value 0-10V or 4-20mA.

8. An automatic unloading and metering system for aluminum box packaging, characterized in that: include: Human-machine interface for the operator to input the target packaging weight and set the target packaging weight for each aluminum box; The weighing sensor is used to detect the actual weight of the aluminum box in real time and transmit the detected actual weight signal to the PLC controller; A PLC controller is used to receive actual weight data from a weighing sensor, calculate an error value between a target weight and an actual weight, and execute a PID control algorithm based on the error value to output a regulating signal to control a material unloading rate of the unloading device; The unloading equipment dynamically adjusts the working state and changes the unloading rate according to the regulation signal output by the PLC controller, so that the actual weight of the aluminum box is close to the target weight; During the unloading process, the weighing sensor continuously monitors the actual weight of the aluminum box, and the PLC controller adjusts the PID control parameters in real time according to the new feedback data; when the actual weight of the aluminum box reaches the target weight and the error value is within the predetermined tolerance range, the PLC controller automatically sends a signal to stop unloading and completes the aluminum box packaging.

9. An electronic device, characterized in that: The invention comprises a memory, a processor and a computer program stored in the memory and executable on the processor. When the processor executes the program, the automatic blanking and metering method for aluminum box packaging as described in any one of claims 1 to 7 is implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the program is executed by a processor, the automatic blanking and metering method for aluminum box packaging as described in any one of claims 1 to 7 is implemented.

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