Reverse power source type cementing power system and position control method

Abstract

The invention provides a reverse power source type cementing power system. The reverse power source type cementing power system comprises a cementing frame and a single-drive servo motor arranged above the cementing frame through a support. The gear belt conveying structure, the gear belt transmission structure and the encoder are arranged on the cementing frame; a gear belt conveying structure is directly driven by an upper-arranged independent-drive servo motor, and a reverse power source type mechanical structure which transmits power to a bottom power distribution structure at the same time is adopted, so that the problem of large motor load fluctuation in a traditional driving mode is solved. The invention further provides a position control method for the system. The method comprises the following steps that the reference sensor senses and triggers a signal; and acquiring a position value as a reference encoder value b, determining a coordinate system offset compensation amount according to a preset sensor reference position value a, and converting an absolute position A in combination with a position value B fed back by the encoder. Through intelligent combination of reference sensor triggering and encoder sampling, a set of position sensing system independent of the absolute origin of the encoder is constructed.

Description

Technical Field

[0001] This invention relates to the field of book binding equipment technology, specifically to a reverse power source binding power system and position control method. Background Technology

[0002] Perfect binding equipment is a core component of the modern printing and publishing industry, responsible for processing loose book blocks into sturdy books. A typical perfect binding production line includes a series of continuous processes such as book block conveying, clamping, rough and fine milling of the spine, slotting, applying base glue, side glue, and cover gluing. These processes are usually carried by a main conveyor system that moves the book blocks, with multiple branch power mechanisms performing actions at corresponding stations. Therefore, the power distribution and position control accuracy of the entire system directly determine the final book binding quality and production efficiency.

[0003] In existing technologies, the drive systems of adhesive bonding equipment commonly employ two mainstream layouts: one is to integrate the drive motor within the middle or bottom of the equipment frame, simultaneously driving the main conveyor chain and various branch power mechanisms through a complex transmission shaft and gear system; the other is to use distributed drive, where servo motors are individually configured for some critical workstations. While the first centralized drive method has a relatively simple structure, the main motor load fluctuates significantly, especially when powering multiple high-load workstations such as milling and gluing simultaneously. This can easily lead to speed fluctuations or even momentary jamming of the main conveyor chain, exacerbating mechanical wear and causing errors in the position feedback signal dependent on the main drive shaft encoder. The second distributed drive method, while reducing the load on the main motor, increases the complexity, cost, and difficulty of synchronization and coordination in system control. Summary of the Invention

[0004] This invention proposes a reverse power source type adhesive binding power system, which solves the technical problems of severe load fluctuations, complex transmission chains, and poor system stability caused by the built-in motor in existing adhesive binding equipment.

[0005] The technical solution of this invention is implemented as follows: The reverse power source type binding power system includes a binding frame and a self-drive servo motor mounted on top of the binding frame via a bracket; A gear belt conveyor structure is installed on the binding frame and directly driven by the output shaft of a dedicated servo motor. A book core clamping component located outside the binding frame is linked to the gear belt conveyor structure. A gear belt drive structure is installed inside the binding frame and driven by the output shaft of a dedicated servo motor. An encoder located in the binding frame is linked to the gear belt drive structure. It also includes sensors mounted on the binding frame to monitor the position of the book block clamping components.

[0006] Furthermore, it also includes a power distribution structure located at the bottom of the adhesive frame and connected to the output shaft of the independent drive servo motor.

[0007] Furthermore, the gear belt drive structure includes a driving gear disk, a driven gear disk, and a toothed belt sleeved between the two. The driven gear disk is mounted on the input shaft of the encoder, and the driving gear disk is mounted on the output shaft of the independent drive servo motor.

[0008] Furthermore, the gear belt conveyor structure includes a driving gear disk, a driven gear disk, and a toothed belt sleeved between the two. The driving gear disk and the driven gear disk are located on both sides of the adhesive frame, and the driving gear disk is mounted on the output shaft of the independent drive servo motor.

[0009] Furthermore, it also includes a control unit, which is electrically or signal-connected to the independent drive servo motor, encoder, and sensor.

[0010] The position control method for the system includes the following steps: S1. When the reference sensor detects the sensing plate on the book core clamping component, a trigger signal is generated; S2. In response to the trigger signal, the real-time position value of the current encoder is acquired as the reference encoder value b; S3. Determine the coordinate system offset compensation amount based on the preset sensor reference position value a and reference encoder value b. S4. Based on the coordinate system offset compensation amount and the position value B fed back by the encoder in real time, the absolute position A of the book core clamping component is obtained by conversion.

[0011] Furthermore, the formula used in step S4 is: A = B + (ab).

[0012] Furthermore, an action position sensor is provided at one or more processing stations in the system; when the action position sensor is triggered, the corresponding actuator is controlled to perform an action based on the calculated absolute position A.

[0013] Furthermore, following step S2, a data validity verification step is also included: a) Compare the currently sampled reference encoder value b with the historically stored reference encoder values; b) If the difference between the two exceeds the preset tolerance range, the data collected this time is determined to be abnormal, and the coordinate system offset compensation amount stored in the history is maintained. c) If the difference between the two is within the preset tolerance range, the data collected this time is deemed valid, and the historical stored value is updated using the coordinate system offset compensation amount calculated this time.

[0014] Furthermore, the data validity verification step is skipped when the system is first triggered after each startup, and the coordinate system offset compensation amount is directly established using the data collected for the first time.

[0015] The beneficial effects of the technical solution provided in this application are as follows: 1. This invention solves the problems of poor system stability and high mechanical losses caused by large motor load fluctuations and complex transmission chains in traditional drive methods by adopting a reverse power source mechanical architecture that uses an upper-positioned independent servo motor to directly drive the gear belt conveyor structure and simultaneously transmits power to the lower power structure. This layout frees the main drive motor from numerous branch power loads, allowing it to focus on ensuring the smoothness and synchronization of the main conveyor line. Its own weight and high-speed rotational inertia also create a flywheel effect, effectively smoothing the instantaneous load impact caused by the movements of the lower workstations. This provides a rigid, low-vibration, and highly reliable power foundation for the entire binding system, significantly reducing maintenance costs and extending equipment lifespan. 2. This invention constructs a position sensing system that does not rely on the absolute origin of the encoder by intelligently combining reference sensor triggering and encoder sampling. Through dynamic coordinate system alignment and real-time mapping at the algorithm level, the inherent signal transmission lag error under high-speed operation is intelligently compensated at the system level. In particular, by uniformly using converted absolute position data for control at the same type of motion position sensor, all executed commands naturally contain the same lag, completely overcoming the technical bottleneck of the sharp decrease in accuracy of traditional position control methods under ultra-high-speed conditions, and achieving continuous high-precision tracking of the book block clamping component position during high-speed continuous operation. 3. This invention, by comparing new and old benchmark sampling data in real time, can accurately identify abnormal data caused by sensor mis-triggers, signal interference, etc., and adopt intelligent strategies to maintain stable parameters and trigger alarms. This not only effectively prevents coordinate system errors and batch processing accidents caused by single abnormal data, but also greatly improves the system's operational reliability and production continuity under complex working conditions, achieving a significant leap from passive fault handling to proactive risk prevention, and providing a solid guarantee for the efficient and stable operation of the production line. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the reverse power source adhesive binding power system of the present invention; Figure 2 This is a partial cross-sectional schematic diagram of the reverse power source adhesive binding power system of the present invention; Figure 3 This is a flowchart of the position control method of the present invention; Figure 4 This is a flowchart of the position control method of the present invention.

[0018] In the diagram: 1. Binding frame; 2. Gear belt conveyor structure; 3. Power structure; 31. Input gear disk; 32. Rotary shaft; 33. Steering gearbox; 34. Drive shaft; 4. Independent drive servo motor; 5. Encoder; 6. Book core clamping component; 7. Sensor; 8. Gear belt drive structure; 9. Divider gear disk; 10. Slide rail. Detailed Implementation

[0019] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] like Figure 1 and Figure 2 As shown, the binding frame 1 of this invention is welded from high-strength structural steel, possessing sufficient rigidity and stability to withstand various dynamic loads during system operation. The independent drive servo motor 4 is mounted on top of the binding frame 1 via a specialized mounting bracket; this top-mounted layout is one of the core innovations of this invention. The motor output shaft extends vertically downwards, traversing the entire frame structure, achieving top-to-bottom power transmission.

[0021] The gear belt conveyor structure 2 is located on the upper part of the binding frame 1 and consists of a driving gear disk, a driven gear disk, and an annular toothed belt fitted between them. The driving gear disk is directly fixed to the output shaft of the independent drive servo motor 4, while the driven gear disk is mounted on the other side of the binding frame 1 via a bearing housing. This direct drive method effectively reduces power transmission links and improves transmission efficiency. A slide rail 10 is located below the gear belt conveyor structure 2. This slide rail 10 is fixed to the periphery of the binding frame 1 by a bracket, providing precise guidance for the book block clamping component 6.

[0022] The book block clamping component 6 is slidably connected to the slide rail 10 via a sliding member, and simultaneously fixedly connected to the bottom of the toothed belt of the gear belt conveyor structure 2 via a dedicated connector. This dual connection design allows the book block clamping component 6 to slide smoothly along the slide rail 10 while moving with the belt, effectively preventing shaking and deviation during operation and ensuring the stability of the book block conveying. Each book block clamping component 6 is equipped with a precision sensing element, which works in conjunction with the sensor 7 to achieve position detection.

[0023] Inside the binding frame 1, another gear belt drive structure 8 is installed, which is also directly driven by the output shaft of the independent drive servo motor 4. The gear belt drive structure 8 includes a driving gear disc, a driven gear disc, and a toothed belt fitted between them. The driving gear disc is directly fixed to the output shaft of the independent drive servo motor 4, and the driven gear disc is directly mounted on the input shaft of the encoder 5. This transmission design ensures that the encoder 5 can accurately follow the movement of the main drive system and monitor the system's operating status in real time. The encoder 5 is a high-precision rotary encoder, fixed inside the binding frame 1 by a special mounting bracket, providing excellent dustproof and vibration-damping performance.

[0024] The power distribution structure 3 is located at the bottom of the adhesive frame 1, and its power input end is connected to the output shaft of the independent drive servo motor 4 via a transfer gear disk 9. Specifically, a transfer gear disk 9 is fixedly installed at the bottom of the output shaft of the independent drive servo motor 4, and this gear disk directly meshes with the input gear disk 31 at the input end of the power distribution structure 3. This direct meshing transmission method ensures the reliability and accuracy of power transmission. The input gear disk 31 is fixed to the rotating shaft 32 via a key connection, and the rotating shaft 32 extends downward and is connected to the steering gearbox 33 via a coupling.

[0025] The steering gearbox 33 employs a precision gear transmission mechanism to convert unidirectional rotational motion into bidirectional output. Drive shafts 34 extend from both sides of the steering gearbox 33, transmitting power to the actuators at various workstations such as spine rough milling, finish milling, grooving, bottom gluing, side gluing, and cover gluing via corresponding couplings and transmission mechanisms. This power distribution method enables precise control of multiple processing stations from a single power source.

[0026] Sensor 7 is mounted at a specific position on the binding frame 1 via an adjustable bracket. It employs a high-performance proximity sensor to accurately detect the passage of the sensing element on the book block clamping component 6. To meet the requirements of high-speed and high-precision control, motion position sensors of the exact same model as the reference sensor 7 are also installed at key stations in the system. These sensors use uniform specifications to ensure consistent response characteristics.

[0027] The system's control unit employs a high-speed programmable logic controller (PLC) with a sampling period of up to 0.25 milliseconds, meeting the control requirements under ultra-high-speed operation. The control unit is electrically connected to the independent drive servo motor 4, encoder 5, and various sensors via dedicated cables, acquiring system operating data in real time and outputting control commands.

[0028] like Figure 3-4As shown, the position control method of the present invention is implemented through the following steps: When the system is powered on and started, the book core clamping component 6 begins to operate. When the sensing plate on it first triggers the reference sensor 7, the control unit immediately executes the reference calibration process. During this process, the control unit records the real-time position value of the current encoder 5 as the reference encoder value b, and simultaneously calls the preset sensor reference position value a (usually set to 0), and establishes the initial mapping relationship between the encoder coordinate system and the absolute coordinate system by calculating the offset (ab). The key to this process is to completely keep the zero point position of the encoder 5 unchanged, and to achieve coordinate mapping only through software algorithms.

[0029] After initial calibration, the system enters a high-speed continuous operation mode. In each control cycle, the control unit continuously reads the real-time position value B of the encoder 5 and calculates the precise position A of the book core clamping component 6 in the absolute coordinate system in real time using the core algorithm A=B+(ab). This continuous position conversion process ensures the stability and consistency of the position information, providing a reliable data foundation for subsequent precise control.

[0030] When the book block clamping component 6 moves to each processing station, the motion position sensor installed at the corresponding position is triggered. At this time, the control unit does not use the instantaneous encoder value at the moment the sensor is triggered, but uniformly uses the absolute position A obtained by conversion through the reference coordinate system as the control reference. Since all sensors are of the same model, their inherent response delay time is basically the same, so the control command issued based on the unified absolute position A naturally contains the same hysteresis, thereby achieving error self-cancellation at the system level.

[0031] This compensation mechanism, based on the consistency of hysteresis between sensors of the same model, ensures that the system's positioning accuracy is almost unaffected by operating speed. Under ultra-high-speed operation, when the motion sensor is triggered, even though the actual position of the book core clamping component 6 has passed the trigger point, the control unit, based on the control command issued by the absolute position A, can accurately trigger the actuator at the predetermined position, achieving precise positioning at high speeds.

[0032] To further enhance system reliability, this invention also includes a data validity verification mechanism. During normal system operation, each time the reference sensor 7 is triggered, the control unit compares and analyzes the newly acquired reference encoder value b_new with the historically stored valid value b_old. This comparison process considers not only the normal fluctuation range of the mechanical system but also parameters such as operating speed and load status for comprehensive judgment.

[0033] If the difference between the old and new reference encoder values ​​is within a preset reasonable tolerance range, the system determines that the new data is valid and updates the compensation parameters accordingly, achieving adaptive adjustment of the system. This mechanism enables the system to adapt to slow changes in system parameters caused by temperature variations, mechanical wear, etc., maintaining long-term operational accuracy.

[0034] When abnormal data is detected, the system activates the corresponding protection mechanism. If the difference between the newly acquired reference encoder value and the historical value exceeds the preset tolerance range, the control system will maintain the original stable parameters and continue operating, while recording the abnormal information and triggering an alarm signal. This intelligent fault-tolerant mechanism effectively prevents control errors caused by momentary interference or equipment malfunction, ensuring the continuity and stability of the production process.

[0035] It is important to note that the data validity verification mechanism is automatically skipped when the sensor is triggered for the first time after the system starts up, and the coordinate system offset compensation is directly established using the data collected initially. This design ensures that the system can quickly establish the initial coordinate system, and also ensures the long-term stability and accuracy of the system through continuous verification during subsequent operation.

[0036] In actual operation, the coordinated control of each processing station demonstrated the comprehensive advantages of this method. Based on a unified absolute position A, the actuators of each station can trigger the corresponding process actions at precise moments. Whether it is rough milling or fine milling of the spine, or processes such as gluing and cover wrapping, perfect timing coordination can be achieved under a unified positional reference.

[0037] This control method, based on a unified coordinate system, not only ensures the precise execution of each process but also guarantees the high-speed and stable operation of the entire production line. Especially when handling books of different sizes, the system can quickly adapt through adjustments to software parameters, greatly improving equipment flexibility and production efficiency.

[0038] Through the organic coordination of the above-mentioned stages, this invention constructs a complete high-speed, high-precision position control system. From the initial benchmark establishment to continuous position calculation, to the collaborative work of multiple sensors, and finally to data security assurance, each stage has been meticulously designed and optimized. This control system not only effectively solves the technical challenges encountered by binding equipment in the process of speeding up, but also provides an innovative technical solution for the intelligent upgrading of the entire industry.

[0039] The deep integration of the mechanical structure and control method in this invention embodies the advanced design concept of mechatronics. The mechanical layout of the reverse power source provides a stable operating foundation for the control system, while the intelligent position control method fully utilizes the performance potential of the mechanical structure. The two complement each other and together achieve the high precision and high stability requirements of the binding equipment under high-speed operation.

[0040] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A counter power source type gluing power system, characterized by, The bookbinding frame (1) and the single-drive servo motor (4) arranged above the bookbinding frame (1) through the support; The gear belt conveying structure (2) is arranged on the bookbinding frame (1) and directly connected with the output shaft of the single-drive servo motor (4), and the book core clamping component (6) located outside the bookbinding frame (1) is connected with the gear belt conveying structure (2); The gear belt transmission structure (8) is arranged in the bookbinding frame (1) and driven by the output shaft of the single-drive servo motor (4), and the encoder (5) located in the bookbinding frame (1) is connected with the gear belt transmission structure (8); The sensor (7) arranged on the bookbinding frame (1) is used to monitor the position of the book core clamping component (6).

2. The counter-power source type bookbinding power system according to claim 1, wherein The split power structure (3) arranged at the bottom of the bookbinding frame (1) is in transmission connection with the output shaft of the single-drive servo motor (4).

3. The counter-power source type bookbinding power system according to claim 1, wherein The gear belt transmission structure (8) comprises a driving gear disc, a driven gear disc and a toothed belt sleeved between the two, the driven gear disc is arranged on the input shaft of the encoder (5), and the driving gear disc is arranged on the output shaft of the single-drive servo motor (4).

4. The counter-power source type bookbinding power system according to claim 1, wherein The gear belt conveying structure (2) comprises a driving gear disc, a driven gear disc and a toothed belt sleeved between the two, the driving gear disc and the driven gear disc are respectively arranged on both sides of the bookbinding frame (1), and the driving gear disc is arranged on the output shaft of the single-drive servo motor (4).

5. The counter-power source type gluing power system according to any one of claims 1-4, characterized in that, The control unit is in electrical connection or signal connection with the single-drive servo motor (4), the encoder (5) and the sensor (7).

6. A position control method for the system as claimed in claim 5, characterized in that, The method comprises the following steps: S1, when the reference sensor senses the sensing sheet on the book core clamping component, a trigger signal is generated; S2, in response to the trigger signal, the real-time position value of the current encoder is collected as the reference encoder value (b); S3, the coordinate system offset compensation amount is determined according to the preset sensor reference position value (a) and the reference encoder value (b); S4, based on the coordinate system offset compensation amount and the subsequent real-time feedback position value (B) of the encoder, the absolute position (A) of the book core clamping component is obtained through conversion.

7. The position control method according to claim 6, wherein The formula for the S4 step is: A=B+(a-b).

8. The position control method according to claim 7, wherein An action position sensor is arranged at one or more processing stations of the system; when the action position sensor is triggered, the corresponding execution element performs an action based on the absolute position (A) obtained after conversion.

9. The position control method according to claim 7, wherein After the S2 step, a data legitimacy verification step is further included: a) comparing the reference encoder value (b) obtained by the current sampling with the historically stored reference encoder value; b) if the difference between the two values exceeds the preset tolerance range, it is determined that the current collection data is abnormal, and the historically stored coordinate system offset compensation amount is maintained; c) if the difference between the two values is within the preset tolerance range, it is determined that the current collection data is legal, and the coordinate system offset compensation amount calculated this time is used to update the historically stored value.

10. The position control method according to claim 9, wherein The data legitimacy verification step is skipped when triggered for the first time after the system is started each time, and the coordinate system offset compensation amount is established directly using the data collected for the first time.

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