Multi-instruction parallel control numerical control system and method for radial forging machine

Abstract

The invention discloses a multi-instruction parallel control numerical control system and method for a radial forging machine, and the system comprises an upper computer system, a PLC (Programmable Logic Controller) control system, a motion control system, a sensor collection system and an execution device, the motion control system realizes multi-axis cooperative trajectory planning through the virtual axis module; the method comprises five steps of pass program editing, instruction classification analysis, collaborative logic decision, multi-axis closed-loop execution and automatic pass switching. Through instruction set programming and linkage control decision making, the pass switching time is shortened to 0.4 second, the multi-axis position control precision is improved to + / -0.1 mm, complex processes such as step shaft positioning and cone forging are supported, the forge piece type is expanded by 60%, the material loss is reduced by 10%, and the intelligent level and the production efficiency of the radial forging machine are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of automated control technology for radial forging machines, specifically to a multi-instruction parallel control numerical control system and method for radial forging machines. Background Technology

[0002] The existing radial forging mill control system has three major defects: 1) Limited pass programming: Only hammer adjustment (RL axis) and chuck speed parameter programming are supported; pass parameterization of auxiliary units (such as centering devices and material support rollers) cannot be edited. 2) Lack of linkage control: Multi-axis motion relies on fixed logic, making it impossible to achieve axis coordination in complex processes such as conical / hollow forging; 3) Insufficient precision: The single auxiliary unit parameter leads to workpiece scratches or dimensional deviations.

[0003] For example, a steel plant's radial forging machine suffered from a scrap rate of up to 15% for tapered forgings because the step shaft positioning pass could not be programmed. Therefore, a high-precision CNC system that supports parallel control of multiple instructions is needed. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-instruction parallel control CNC system and method for radial forging machines, which solves the problems of poor multi-task coordination, weak process adaptability, and low precision in existing systems, and realizes high-precision forming of complex forgings.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A multi-instruction parallel control CNC system for a radial forging machine includes a host computer system, a PLC control system, a motion control system, a sensor acquisition system, and an execution device. The host computer system includes an industrial control computer and a human-machine interface, and supports multi-instruction programming and issuance. The PLC control system communicates with the host computer system for instruction parsing and logical decision-making. The motion control system receives PLC commands to achieve multi-axis collaborative closed-loop control; The sensor acquisition system is connected to the actuator and provides real-time feedback of shaft status data. The actuator includes a hydraulic cylinder, a hydraulic motor, and an electric motor, which drive the forging machine hammer, chuck, and auxiliary units to move.

[0006] Preferably, the host computer system includes an instruction set module, a pass module, and a data storage module. The instruction set module stores axis control instructions, function instructions, and auxiliary instructions. The pass module provides 99 nameable programming windows, each window supports 99 lines of pass programs, and each pass allows editing of 20 instructions. The data storage module stores pass parameters and process data.

[0007] Preferably, the PLC control system includes a CNC decoding module, a programmed forging decision module, and a pass switching module. The CNC decoding module parses the host computer instructions into axis instructions, function instructions, or auxiliary instructions. The programmed forging decision module executes collaborative control decisions based on the instruction logic. The pass switching module automatically switches to the next pass after all axes have moved to their positions.

[0008] Preferably, the motion control system includes: a virtual axis control module and an axis motion control module, wherein the virtual axis control module generates multi-axis cooperative motion planning signals; and the axis motion control module performs closed-loop control of position, speed or force with an accuracy error ≤0.1mm.

[0009] Preferably, the sensor acquisition system includes a high-resolution displacement sensor and a pressure sensor, a signal isolation module, and a dual-channel acquisition module; the high-resolution displacement sensor with an accuracy ≤1μm and the pressure sensor with an accuracy ≤0.1%FS respectively acquire servo axis position data and hydraulic cylinder pressure data in real time; the signal isolation module performs anti-interference processing on the sensor signals; the servo axis sensor signals of the dual-channel acquisition module are directly connected to the motion control system, and the auxiliary axis sensor signals are connected to the PLC control system.

[0010] A method for multi-instruction parallel control of a radial forging mill, the method employing the aforementioned multi-instruction parallel control CNC system for radial forging mills, includes the following steps: Step 1: Pass Program Editing: In the pass module of the host computer system, edit the pass program according to the process requirements: A single track can support ≤20 parallel instructions, including axis control instructions such as G00 positioning instructions, function instructions such as M31 hammer synchronization instructions, and auxiliary instructions such as S12 material support roller pressure instructions. The data for each pass is stored in the data storage module and logical conflicts are automatically checked. Step 2, Instruction Parsing: The numerical control decoding module of the PLC control system parses the instructions into three categories: The axis command is parsed as the axis name and motion parameters, such as "G00 X100" which means the chuck axis is positioned to 100mm. Functional instructions are parsed into collaborative function codes, such as M31, which corresponds to the synchronization of the speed of the hammer and the chuck. The auxiliary command is parsed into auxiliary equipment parameters, such as the pressure value of the material support roller corresponding to S12; Step 3, Collaborative Decision Making: Execution of the Programmed Forging Decision Module: Generate axis coordination timing based on instruction logic relationships, such as pausing chuck feed during hammer forging; Servo axis commands are assigned to the motion control system, while auxiliary axis commands are directly controlled by the PLC. Step 4, Axis Control Execution: The virtual axis control module generates multi-axis spatiotemporal collaborative trajectories, such as planning the phase difference between the chuck feed and the hammer forging to be ≤5ms; The axis motion control module combines real-time feedback data from the sensor acquisition system to perform position / velocity closed-loop control with an accuracy error of ≤0.1mm. Step 5: Pass switching: When all servo axes move to the target tolerance range with a position error ≤0.1mm and the auxiliary axis status meets the standard, the pass switching module automatically triggers the next pass program.

[0011] Compared with the prior art, the present invention has the following advantages: (1) This invention supports the parallel editing and execution of 20 instructions in a single pass through the host computer system. Combined with the automatic pass switching mechanism, the switching time between traditional passes is reduced from 1.2 seconds to 0.4 seconds. At the same time, it breaks through the fixed pass programming limitation and realizes the fully automatic control of complex processes such as stepped shaft positioning and conical forging. This increases the types of workpieces that the equipment can forge, reduces material loss, and greatly expands the application scenarios of radial forging machines.

[0012] (2) Based on the virtual axis module of the motion control system, the present invention dynamically plans the time and space motion trajectory of the hammer, chuck and auxiliary unit (such as phase difference ≤ 5ms), and with the real-time feedback of the high-resolution displacement sensor (1μm accuracy) and pressure sensor, the hydraulic actuator is dynamically adjusted through the closed-loop control module to ensure that the multi-axis collaborative position error is ≤ 0.1mm, effectively solving the problems of workpiece scratches and dimensional deviations, and achieving the forming quality target.

[0013] (3) The present invention adopts an instruction set-based CNC programming interface, which allows process personnel to directly edit function instructions (such as the chuck and hammer synchronization instruction G02) and auxiliary parameters (such as the A material support roller position VA160). The PLC system automatically parses the instruction logic relationship through the decoding module, and the decision module coordinates the action of the servo axis and the auxiliary axis, reducing the intensity of manual intervention, improving the efficiency of human-machine interaction by 50%, and reducing the scrap rate caused by operational errors. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the control objects (hammer, chuck, material support roller, etc.) of the radial forging machine of the present invention. Figure 2 This is a system schematic diagram of the present invention; Figure 3 This is a schematic diagram of the machining step shaft structure in an embodiment. Detailed Implementation

[0015] The present invention will be further described in detail below with reference to specific embodiments.

[0016] like Figure 1As shown, a multi-instruction parallel control CNC system for a radial forging machine includes a host computer system 1, a PLC control system 2, a motion control system 3, a sensor acquisition system 4, and an execution device 5. The host computer system 1 includes an industrial computer and a human-machine interface, supporting multi-instruction programming and issuance; the PLC control system 2 communicates with the host computer system for instruction parsing and logic decision-making; the motion control system 3 receives PLC instructions to realize multi-axis collaborative closed-loop control; the sensor acquisition system 4 is connected to the actuator 5 to provide real-time feedback of axis status data; the actuator 5 includes hydraulic cylinders, hydraulic motors, and electric motors to drive the forging machine hammer, chuck, and auxiliary unit movements.

[0017] The host computer system 1 includes an instruction set module 6, a pass module 7, and a data storage module 8. The instruction set module 6 stores axis control instructions, function instructions, and auxiliary instructions. The pass module 7 provides 99 nameable programming windows, each window supports 99 lines of pass programs, and each pass allows editing of 20 instructions. The data storage module 8 stores pass parameters and process data.

[0018] The PLC control system 2 includes a numerical control decoding module 10, a programmed forging decision module 11, and a pass switching module 12. The numerical control decoding module 10 parses the host computer instructions into axis instructions, function instructions, or auxiliary instructions. The programmed forging decision module 11 executes collaborative control decisions according to the instruction logic relationship. The pass switching module 12 automatically switches to the next pass after all axes have moved to their positions.

[0019] The motion control system 3 includes a virtual axis control module 14 and an axis motion control module 15. The virtual axis control module 14 generates multi-axis cooperative motion planning signals. The axis motion control module 15 performs closed-loop control of position, speed or force with an accuracy error ≤0.1mm.

[0020] The sensor acquisition system 4 includes a high-resolution displacement sensor and a pressure sensor, a signal isolation module, and a dual-channel acquisition module. The high-resolution displacement sensor with an accuracy of ≤1μm and the pressure sensor with an accuracy of ≤0.1%FS acquire servo axis position data and hydraulic cylinder pressure data in real time, respectively. The signal isolation module performs anti-interference processing on the sensor signals. The servo axis sensor signals of the dual-channel acquisition module are directly connected to the motion control system 3, and the auxiliary axis sensor signals are connected to the PLC control system 2.

[0021] like Figure 2 As shown, a multi-instruction parallel control method for a radial forging mill, employing the aforementioned multi-instruction parallel control CNC system for radial forging mills, includes the following steps: Step 1, Pass Program Editing: In the pass module 7 of the host computer system 1, edit the pass program according to the process requirements: A single track can support ≤20 parallel instructions, including axis control instructions such as G00 positioning instructions, function instructions such as M31 hammer synchronization instructions, and auxiliary instructions such as S12 material support roller pressure instructions. The track data is stored in data storage module 8 and logical conflicts are automatically checked. Step 2, Instruction Parsing: The numerical control decoding module 10 of the PLC control system 2 parses the instructions into three categories: The axis command is parsed as the axis name and motion parameters, such as "G00 X100" which means the chuck axis is positioned to 100mm. Functional instructions are parsed into collaborative function codes, such as M31, which corresponds to the synchronization of the speed of the hammer and the chuck. The auxiliary command is parsed into auxiliary equipment parameters, such as the pressure value of the material support roller corresponding to S12; Step 3, Collaborative Decision Making: Execution of the Programmed Forging Decision Module 11: Generate axis coordination timing based on instruction logic relationships, such as pausing chuck feed during hammer forging; Servo axis commands are assigned to motion control system 3, while auxiliary axis commands are directly controlled by the PLC. Step 4, Axis Control Execution: The virtual axis control module 14 generates a multi-axis spatiotemporal collaborative trajectory, such as planning the phase difference between the chuck feed and the hammer forging to be ≤5ms; The axis motion control module 15, combined with the real-time feedback data from the sensor acquisition system 4, performs position / velocity closed-loop control with an accuracy error ≤0.1mm. Step 5: Pass switching: When all servo axes move to the target tolerance range with a position error ≤0.1mm and the auxiliary axis status meets the standard, the pass switching module 12 automatically triggers the next pass program.

[0022] Example: Taking the hot forging production of forgings using an LSJX16 / 2MN radial forging mill as an example, the incoming material is tool steel with a diameter of 160mm and a length of 937.3mm, which is then hot forged. The finished product after forging is a shaft-like product with a tapered shape and a stepped profile, as shown in the figure below. The hammer in the tooling has a forming surface length of 80mm and a pre-forging angle of 153°. The forging program is edited according to the principle of constant volume.

[0023] The forging sequence is as follows: (1) Forge a workpiece with a diameter of 160mm into a workpiece with a diameter of 150mm.

[0024] (2) The length of the forged shaft end is 500mm and the diameter is 100mm.

[0025] (3) Forged cone, cone with a taper of 1:6, length of 300mm, and diameters of 100mm and 150mm at both ends respectively.

[0026] (4) The reserved middle section is 300mm long and 150mm in diameter, and is not forged.

[0027] (5) The length of the forged step is 400mm.

[0028] (6) Leave a 100mm margin at the end of the forging. Lane procedure and instructions: N01 VRA10.0 / / Automatic feeding from the feeding side, the billet is handed over to chuck A.

[0029] N02 RL150.0 H5.0 M42 S05 M130 PS50.0 PZ40.0 G00 / / Adjust the hammer head at a speed of 5.0mm / s to a diameter of 150.0mm; start reverse clamping; start rotation of chucks A and B; start rotational oscillation braking of chucks A and B; set the main clamping of chucks A and B to 50KN; set the reverse clamping of chucks A and B to 40KN; accurately position each axis.

[0030] N03 B6000.0 FB40 K8 UA800.0 UE0000.0 I1.14 WA165.0 WB155.0 VA165.0VB155.0 M61 M63 M56 M60 / / Chuck B is positioned at 6000.0mm; Chuck B feed speed is 40.0mm / s; Chuck B maintains clamping pressure and Chuck A maintains centering pressure; Chuck B clamps the forging after it reaches 800.0mm in diameter; it stops after traveling 0mm after tail identification; forging ratio is 1.14; the centering device on side A rises to 165.0mm; the centering device on side B rises to 155.0mm; the material support roller on side A rises to 165.0mm, and the material support roller on side B rises to 155.0mm. The starting positions of the centering device on side A, the centering device on side B, the material support roller on side A, and the material support roller on side B are controlled.

[0031] N04 RL155.0 H8.0 G40 / / Adjust the hammer head rapidly at a speed of 8.0mm / s to a diameter of 155.0mm; initial positioning.

[0032] N05 A5000.0 FA40.0 K6 UA700.0 UE000 / / Chuck A is positioned at 5000.0mm; Chuck A retraction speed is 40.0mm / s; Chuck A maintains clamping pressure, Chuck B maintains centering pressure; Chuck A clamps the forging after it is identified at 700.0mm; forging ratio is 1.0.

[0033] N06 RL100.0 H3.5.0 G00 / / The hammer head is adjusted at a speed of 3.5mm / s to a diameter of 100.0mm; all axes are precisely positioned.

[0034] N07 B460.0 FB40.0 K8 UA800.0 UE0000.0 I2.25 / / Chuck B is positioned at 460mm; Chuck B feed speed is 40mm / s; Chuck B maintains clamping pressure and Chuck A maintains centering pressure; Chuck B clamps the workpiece after it is identified at 800.0mm; it stops after traveling 0mm after the tail end is identified; forging ratio is 2.25.

[0035] N08 B640.0 FB20.0 RL150.0 G02 / / The B chuck clamps the workpiece and travels at a speed of 20.0mm / s to 640.0mm; the hammer head adjustment R-axis and L-axis are synchronized with the chuck position, the speed adjustment of the hammer head to the 150.0mm diameter position is calculated and the hammer head adjustment position speed is controlled, and the hammer head position is continuously adjusted according to the calculated hammer head adjustment speed, so that the chuck and hammer head reach each sub-point in the process at the same time; the A or B axis moves synchronously with the RL axis.

[0036] N09 RL155.0 H5.0 G40 / / Adjust the hammer head at a speed of 5.0mm / s to a diameter of 150.0mm; initial positioning.

[0037] N10 B1020.0 FB20.0 G00 / / The B chuck holds the workpiece and moves it to the 1020.0mm position at a speed of 20.0mm / s; each axis is precisely positioned.

[0038] N11 RL110.0 H5.0 / / Adjust the hammer head at a speed of 5.0mm / s to a diameter of 110.0mm; each axis is precisely positioned.

[0039] N12 B1420.0 FB20.0 / / The B chuck moves at a speed of 20.0mm / s and positions itself at 1420.0mm.

[0040] N13 RL155.0 H8.0 B+300 M131 G40 / / Adjust the hammer head rapidly at a speed of 8.0mm / s to a diameter of 150.0mm; B chuck moves 300mm relative to the other; stop the oscillation braking of A and B chucks; roughly (quickly) position each axis.

[0041] N14 S00 M43 VRB10.0 / / Stop rotation of chucks A and B; disable reverse clamping; automatic unloading from the unloading side.

[0042] N15 M62 M64 M57 M61 M30 / / Close the centering clamp on side A to its maximum opening; close the centering clamp on side B to its maximum opening; lower the material support roller on side A to its lowest position; lower the material support roller on side B to its lowest position; the pass program jumps to the first pass program.

[0043] Step S1 (Track Order Editing): N01 to N15 are lane number instructions 10; N001 (Track Number 1); G00, G02 (high-precision positioning, G40 medium-speed positioning); VRA10 (Automatic Feeder); RL150.0 (hammer head adjustment: R-axis and L-axis are simultaneously adjusted to the 150.0mm diameter position); H5 (Hammer head adjustment R-axis and L-axis adjustment speed is 5mm / s) Step S2 (Instruction Parsing): The PLC numerical control decoding module parses the instructions into: Axis commands: such as B460 (B chuck is positioned at 460mm; FB40 (B chuck feed speed is 40mm / s). Function command: G02 (A or B axis moves synchronously with RL axis); Auxiliary command: M61 (A-side centering device activated); Step S3 (Collaborative Decision Making): Programmatic forging decision module 11 executes instruction allocation: Based on the track module and the analysis results in S2, axis commands and function commands are assigned to motion control system 3; auxiliary commands are assigned to PLC control system 2 for logic control.

[0044] For example: N02 RL150.0 H5 M42 M61 M63 G00 PS50 PZ40 Assign RL150.0, H5, PS50, PZ40, and G00 to motion control system 3; assign M42, M61, and M63 to the PLC control system for logic judgment.

[0045] Step S4 (Axis control execution): For example: N08 B640 FB20 RL150 G02 The virtual axis control module allows the A or B axis to move synchronously with the RL axis, and plans the speed of hammer adjustment according to the actual movement position and speed of the chuck and the target position of the hammer adjustment. According to function code G02, axis A or B moves synchronously with axis RL. The chuck moves to the target position at a set speed, and the hammer moves in coordination with the chuck. Within the same time period, the hammer adjustment speed is determined in real time according to the chuck position and the target position of the hammer adjustment, so as to achieve coordinated control of the real-time movement position of the chuck and the real-time positioning position of the hammer adjustment. Among them, the chuck position and speed are the main factors, and the hammer adjustment speed is adjusted according to the real-time position of the chuck movement to maintain a consistent positional relationship.

[0046] Axis motion control executes closed-loop control of each axis according to the virtual axis trajectory plan. A position signal is sent after each axis reaches the target.

[0047] Step S5 (Track Switching): When the sensor detects that the axis position control executed in the line of instructions has reached the tolerance zone required by the instruction, it is determined that the position has been executed. Auxiliary instructions and function instructions are executed quickly. After all the instructions in the line have been executed, it is determined that the line of instructions has been executed. It then automatically jumps to the next line of instructions until the instructions have been executed. Finally, it jumps to the first pass to wait for material loading.

[0048] For example: N08 B640 FB20 RL150 G02 When the chuck position deviation is ≤0.1mm and the hammer head adjustment position deviation is ≤0.1mm, the next pass will be executed automatically.

[0049] The above are merely preferred embodiments of the present invention. It should be noted that, for those skilled in the art, based on the technical teachings provided by the present invention and as common knowledge in the field, other equivalent modifications and improvements can be made, and these should also be considered within the scope of protection of the present invention.

Claims

1. A multi-instruction parallel control numerical control system for a radial forging machine, characterized by: The system comprises an upper computer system (1), a PLC control system (2), a motion control system (3), a sensor acquisition system (4) and an execution device (5); The upper computer system (1) comprises an industrial computer and a man-machine interface, supports multi-instruction pass programming and issuing; The PLC control system (2) communicates with the upper computer system, and is used for instruction analysis and logical decision-making; The motion control system (3) receives the PLC instruction, and realizes multi-axis collaborative closed-loop control; The sensor acquisition system (4) is connected with the execution device (5), and real-time feedback of shaft state data is realized; The execution device (5) comprises a hydraulic cylinder, a hydraulic motor and a motor, and drives the hammer head, the chuck and the auxiliary unit of the radial forging machine to move.

2. The open-die forging machine multi-instruction parallel control numerical control system according to claim 1, characterized in that: The upper computer system (1) comprises an instruction set module (6), a pass module (7) and a data storage module (8), the instruction set module (6) comprises storage shaft control instructions, function instructions and auxiliary instructions; the pass module (7) provides 99 programmable windows, each window supports 99 pass programs, and each pass allows editing of 20 instructions; the data storage module (8) stores pass parameters and process data.

3. The open-die forging machine multi-instruction parallel control numerical control system according to claim 2, characterized in that: The PLC control system (2) comprises a numerical control decoding module (10), a programmed forging decision module (11) and a pass switching module (12), the numerical control decoding module (10) analyzes the upper computer instruction into shaft instructions, function instructions or auxiliary instructions; the programmed forging decision module (11) executes collaborative control decision-making according to the logical relationship of the instructions; and the pass switching module (12) automatically switches to the next pass after all the shafts move to the position.

4. The open-die forging machine multi-instruction parallel control numerical control system according to claim 2 or 3, characterized in that: The motion control system (3) comprises a virtual shaft control module (14) and a shaft motion control module (15), the virtual shaft control module (14) generates multi-axis collaborative motion planning signals; and the shaft motion control module (15) executes closed-loop control of position, speed or force, and the precision error is less than or equal to 0.1 mm.

5. The open-die machine multi-instruction parallel control numerical control system according to claim 4, characterized in that: The sensor acquisition system (4) comprises high-resolution displacement sensors and pressure sensors, a signal isolation module and a double-channel acquisition module; the high-resolution displacement sensors (with an accuracy of less than or equal to 1 μm) and the pressure sensors (with an accuracy of less than or equal to 0.1% FS) respectively acquire real-time servo shaft position data and hydraulic cylinder pressure data; the signal isolation module performs anti-interference processing on the sensor signals; and the double-channel acquisition module directly connects the servo shaft sensor signals to the motion control system (3), and connects the auxiliary shaft sensor signals to the PLC control system (2).

6. A method for multi-instruction parallel control of a radial forging machine, the method using the multi-instruction parallel control numerical control system of any one of claims 1 to 5, characterized in that The method comprises the following steps: Step one, pass program editing: in the pass module (7) of the upper computer system (1), pass programs are edited according to process requirements: Single pass supports less than or equal to 20 parallel instructions, including shaft control instructions (such as G00 positioning instructions), function instructions (such as M31 hammer head synchronization instructions) and auxiliary instructions (such as S12 material supporting roller pressure instructions); Pass data is stored in the data storage module (8) and automatically checked for logical conflicts; Step two, instruction analysis: the numerical control decoding module (10) of the PLC control system (2) analyzes the instructions into three categories: Axis command is parsed into axis name and motion parameters (e.g. "G00 X100" is parsed into the clamp axis positioning to 100mm); Function command is parsed into collaborative function code (e.g. M31 corresponds to the hammer and clamp speed synchronization); Auxiliary command is parsed into auxiliary device parameters (e.g. S12 corresponds to the material supporting roller pressure value); Step three, collaborative decision: the programmed forging decision module (11) executes: According to the instruction logic relationship, the axis coordination sequence is generated (e.g. the clamp feeding is paused when the hammer is forging); Servo axis command is distributed to the motion control system (3), and auxiliary axis command is directly controlled by PLC; Step four, axis control execution: the virtual axis control module (14) generates multi-axis space-time coordination trajectory (e.g. the phase difference between the planned clamp feeding and hammer forging is ≤5ms); The axis motion control module (15) combines the real-time feedback data of the sensor acquisition system (4) to execute position / speed closed-loop control (precision error ≤0.1mm); Step five: pass switching: when all servo axes move to the target tolerance range (position error ≤0.1mm) and the auxiliary axis state meets the standard, the pass switching module (12) automatically triggers the next pass program.

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