Power regulation method and system for pipe threading machine in steel pipe plant based on PLC logic control

Abstract

This invention relates to the field of metallurgical control technology, specifically to a power adjustment method and system for a steel pipe threading machine based on PLC logic control. The method includes: acquiring real-time load current of the main drive mechanism in the threading machine, real-time position data of the billet on the conveyor rollers, real-time temperature data of the billet, and real-time feedback torque of the main drive mechanism; when the billet reaches the biting start position, the PLC obtains a first target torque based on the temperature-corrected reference torque, and generates a control signal to control the main drive mechanism after deviation comparison; after the billet is bitten, the load current waveform is identified to obtain a status signal, the coupling relationship between current fluctuation and temperature is analyzed during the stabilization piercing stage to obtain a speed-torque composite adjustment coefficient, the roller speed and the second target torque are adjusted, and the output torque of the main drive mechanism is adjusted in real time through torque deviation judgment; this invention can improve the efficiency of power adjustment of a steel pipe threading machine based on PLC logic control.

Description

Technical Field

[0001] This invention relates to the field of metallurgical control technology, and in particular to a power adjustment method and system for a pipe threading machine in a steel pipe plant based on PLC logic control. Background Technology

[0002] The power adjustment of the tube threading machine in a steel pipe plant is a core part of the steel pipe piercing process. The existing power adjustment methods of tube threading machines mostly use fixed torque and speed parameters for control, without taking into account key data such as the real-time temperature, position and load changes of the billet and the main drive mechanism. They also lack targeted adaptation for the differences in steel grades of the billet. There is no dynamic correction mechanism for the torque setting during the billet biting stage, which can easily cause equipment impact or billet biting failure. It is difficult to adapt to the dynamic changes in the production process.

[0003] During the stable piercing stage of the tube threading machine, the existing technology has not explored the relationship between the load current fluctuation of the main drive mechanism and the billet temperature. It only adjusts the torque or conveying speed in a single dimension, resulting in large load fluctuations in the main drive mechanism and insufficient stability of the piercing process. This affects the processing accuracy of steel pipe piercing and reduces the service life of the transmission equipment. The real-time performance and accuracy of the overall power adjustment do not meet the requirements of modern steel pipe production. Therefore, how to improve the efficiency of power adjustment of the tube threading machine has become an urgent problem to be solved. Summary of the Invention

[0004] This invention provides a power adjustment method and system for a pipe threading machine in a steel pipe plant based on PLC logic control, in order to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides a power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control, comprising:

[0006] A1. Obtain the real-time load current of the main drive mechanism in the tube threading machine, the real-time position data of the tube blank on the conveyor roller, the real-time temperature data of the tube blank, and the real-time feedback torque of the main drive mechanism.

[0007] A2. When the real-time position data reaches the preset bite start position threshold, the programmable logic controller dynamically corrects the reference torque value extracted from the historical production data based on the real-time temperature data to obtain the first target torque value of the tube threading machine.

[0008] A3. Compare the deviation between the first target torque value and the real-time feedback torque, and generate the first drive control signal of the tube threading machine based on the deviation value after comparison and send it to the main drive mechanism.

[0009] A4. After the main drive mechanism bites into the tube blank, the programmable logic controller identifies the waveform of the continuously acquired real-time load current to obtain the status signal of the tube threading machine.

[0010] A5. When the status signal indicates that the piercing stage has been entered, analyze the coupling relationship between the fluctuation mode of the real-time load current and the real-time temperature data to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjust the conveying speed of the conveying roller and the second target torque value of the main drive mechanism according to the speed-torque composite adjustment coefficient.

[0011] A6. During the stable piercing stage, the continuously acquired real-time feedback torque is compared with the second target torque value to determine the deviation. Based on the determined deviation value, a second drive control signal for the tube piercing machine is generated and sent to the main drive mechanism to adjust the output torque of the main drive mechanism in real time.

[0012] In a preferred embodiment, when the real-time position data reaches a preset bite start position threshold, the programmable logic controller dynamically corrects the reference torque value extracted from historical production data based on the real-time temperature data to obtain the first target torque value of the tube threading machine, including:

[0013] The programmable logic controller continuously compares the real-time position data with the preset bite start position threshold. When the real-time position data reaches the bite start position threshold, it generates a trigger signal for the tube threading machine.

[0014] In response to the trigger signal, the programmable logic controller extracts the average torque value of the steel grade information in the historical piercing process from historical production data based on the steel grade information of the billet, and uses the average torque value as the reference torque value of the tube threading machine.

[0015] Retrieve historical torque records at the same temperature as the real-time temperature data from historical production data to obtain the temperature matching torque value of the tube threading machine;

[0016] The temperature compensation amount of the tube threading machine is obtained by quantifying the difference between the temperature matching torque value and the reference torque value.

[0017] The reference torque value and temperature compensation are used to correct the calculation, and the first target torque value of the tube threading machine is obtained.

[0018] In a preferred embodiment, the formula for calculating the first target torque value is as follows:

[0019] ;

[0020] In the formula, The first target torque value, The reference torque value, This is the temperature compensation amount. The preset dynamic compensation coefficient, This represents the rate of temperature change.

[0021] In a preferred embodiment, the step of comparing the deviation between the first target torque value and the real-time feedback torque, and generating a first drive control signal for the tube threading machine based on the compared deviation value and sending it to the main drive mechanism, includes:

[0022] The first target torque value is mapped to the real-time feedback torque to obtain the torque deviation signal of the tube threading machine.

[0023] The torque deviation signal is input to the proportional-integral regulator in the programmable logic controller for proportional-integral analysis to obtain the initial control quantity of the pipe threading machine.

[0024] The initial control quantity is subjected to a limiting process to obtain the limited control quantity after the initial control quantity is obtained;

[0025] The control quantity after the amplitude limiting is converted from digital to analog to obtain the first drive control signal of the tube threading machine;

[0026] The first drive control signal is sent to the main drive mechanism through the analog output port of the programmable logic controller.

[0027] In a preferred embodiment, after the main drive mechanism bites into the tube blank, the programmable logic controller performs waveform identification on the continuously acquired real-time load current to obtain the status signal of the tube threading machine, including:

[0028] After the main drive mechanism completes the biting action on the tube blank, the programmable logic controller performs waveform truncation on the continuously acquired real-time load current to obtain a current waveform segment of the real-time load current.

[0029] Time-domain features are extracted from the current waveform segment to obtain the waveform rise rate, peak waveform amplitude, and waveform oscillation period of the current waveform segment;

[0030] Based on the waveform rise rate and peak waveform amplitude, the impact load characteristics borne by the main drive mechanism during the billet biting process are analyzed to obtain the biting impact characteristics of the billet.

[0031] Based on the waveform fluctuation period, the fluctuation pattern of the current waveform segment is mined to obtain the fluctuation pattern recognition result of the current waveform segment.

[0032] The bite impact characteristics and fluctuation pattern recognition results are logically combined to obtain the status signal of the tube insertion machine.

[0033] In a preferred embodiment, when the status signal indicates that the piercing stage has been reached, analyzing the coupling relationship between the fluctuation pattern of the real-time load current and the real-time temperature data to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjusting the conveying speed of the conveyor rollers and the second target torque value of the main drive mechanism based on the speed-torque composite adjustment coefficient, includes:

[0034] When the status signal indicates that the pipe-piercing machine has entered the stable piercing stage, the programmable logic controller analyzes the fluctuation cycle of the continuously acquired real-time load current to obtain the fluctuation pattern of the real-time load current.

[0035] Temperature change trend analysis was performed on the real-time temperature data continuously acquired during the stable piercing stage to obtain the temperature gradient characteristics and average temperature characteristics of the tube blank during the piercing process.

[0036] The correlation between the fluctuation mode and the temperature gradient characteristics and the average temperature characteristics is determined to obtain the coupling relationship between the real-time load current and the tube blank.

[0037] Based on the coupling relationship and the deviation between the current fluctuation range of the real-time load current and the reference fluctuation range in the historical production data, the torque adjustment amount of the main drive mechanism and the speed adjustment amount of the conveyor roller are calculated to obtain the speed-torque composite adjustment coefficient of the tube threading machine.

[0038] Based on the speed-torque composite adjustment coefficient, the torque value of the main drive mechanism is corrected before the start of the stable piercing stage to obtain the second target torque value of the main drive mechanism.

[0039] Based on the speed-torque composite adjustment coefficient, the initial conveying speed of the conveyor rollers is dynamically compensated before the start of the stable piercing stage to obtain the adjusted conveying speed of the conveyor rollers.

[0040] In a preferred embodiment, determining the correlation between the fluctuation mode and temperature gradient characteristics and temperature mean characteristics to obtain the coupling relationship between the real-time load current and the tube blank includes:

[0041] By time-registering the fluctuation pattern with temperature gradient characteristics and temperature mean characteristics, a current-temperature correlation data pair between real-time load current and tube blank is constructed.

[0042] Response identification is performed on current-temperature correlation data pairs to obtain the response characteristics of current-temperature correlation data;

[0043] Based on the response characteristics, the coupling relationship between the real-time load current and the tube blank is generated.

[0044] In a preferred embodiment, the formula for calculating the speed-torque composite adjustment coefficient is as follows:

[0045] ;

[0046] This is the speed-torque composite adjustment coefficient. The preset base adjustment coefficient, This represents the current fluctuation range. For reference fluctuation range, This represents the coupling strength coefficient extracted from the coupling relationship. It is a temperature gradient feature. The temperature average characteristic is... The fluctuation frequency of the real-time load current extracted from the fluctuation mode.

[0047] In a preferred embodiment, during the stable piercing stage, the continuously acquired real-time feedback torque is compared with the second target torque value to determine the deviation. Based on the determined deviation value, a second drive control signal for the piercing machine is generated and sent to the main drive mechanism to adjust the output torque of the main drive mechanism in real time, including:

[0048] During the stable piercing stage, the programmable logic controller quantifies the deviation between the continuously acquired real-time feedback torque and the second target torque value to obtain the torque tracking deviation value of the piercing machine.

[0049] The torque tracking deviation value is input to the proportional-integral regulator in the programmable logic controller for control quantity tuning, so as to obtain the torque correction amount after the pipe threading machine is limited;

[0050] The torque correction amount after limiting is algebraically added to the second target torque value to obtain the third target torque value of the pipe threading machine;

[0051] The third target torque value is mapped to the drive signal to obtain the second drive control signal of the pipe threading machine;

[0052] The second drive control signal is sent to the main drive mechanism through the analog output port of the programmable logic controller to track and adjust the output torque of the main drive mechanism in real time.

[0053] To address the aforementioned problems, this invention also provides a power adjustment system for a pipe threading machine in a steel pipe plant based on PLC logic control, the system comprising:

[0054] The data acquisition module is used to acquire the real-time load current of the main drive mechanism in the tube threading machine, the real-time position data of the tube blank on the conveying roller, the real-time temperature data of the tube blank, and the real-time feedback torque of the main drive mechanism.

[0055] The pre-biting torque preset module is used to dynamically correct the reference torque value extracted from historical production data based on real-time temperature data when the real-time position data reaches the preset biting start position threshold, so as to obtain the first target torque value of the tube threading machine.

[0056] The pre-bite torque closed-loop control module is used to compare the deviation between the first target torque value and the real-time feedback torque, and generate the first drive control signal of the tube threading machine based on the deviation value after comparison and send it to the main drive mechanism.

[0057] The bite status identification module is used to identify the waveform of the continuously acquired real-time load current after the main drive mechanism bites the tube blank, and obtain the status signal of the tube threading machine.

[0058] The stable phase coupling adjustment module is used to analyze the coupling relationship between the fluctuation mode of the real-time load current and the real-time temperature data when the status signal indicates that the piercing stage has been entered, so as to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjust the conveying speed of the conveying roller and the second target torque value of the main drive mechanism according to the speed-torque composite adjustment coefficient.

[0059] The torque tracking control module in the stable phase is used to determine the deviation between the continuously acquired real-time feedback torque and the second target torque value during the stable piercing phase. Based on the determined deviation value, it generates a second drive control signal for the tube piercing machine and sends it to the main drive mechanism to adjust the output torque of the main drive mechanism in real time.

[0060] Compared with the prior art, the present invention has the following beneficial effects:

[0061] 1. This invention relies on PLC logic control to realize intelligent adjustment of the power of the tube threading machine. By combining the real-time temperature and position of the tube blank and the operating data of the main drive mechanism, the reference torque is dynamically corrected and the torque deviation is closed-loop controlled. This achieves precise preset and real-time adjustment of the torque during the tube blank biting stage, making the output torque of the main drive mechanism highly compatible with the actual working conditions on the production site, improving the smoothness of the tube blank biting process, effectively reducing the impact loss during equipment operation, and ensuring the operational stability of the transmission mechanism.

[0062] 2. This invention can accurately determine the operating status of the tube threading machine by identifying the waveform of the real-time load current. During the stable piercing stage, it explores the coupling relationship between load current fluctuations and billet temperature, realizing composite coordinated adjustment of speed and torque. At the same time, with the real-time identification and tracking control of torque deviation, the power adjustment has multi-dimensional adaptability and dynamism, which greatly improves the real-time performance and accuracy of the tube threading machine's power adjustment, optimizes the processing effect of steel pipe piercing, and also makes the operating parameters of the conveyor roller and the main drive mechanism form an efficient match, further improving the overall operating efficiency of steel pipe piercing production. Attached Figure Description

[0063] Figure 1 A flowchart illustrating a power adjustment method for a steel pipe threading machine based on PLC logic control, according to an embodiment of the present invention.

[0064] Figure 2 A functional block diagram of a power adjustment system for a steel pipe threading machine in a steel pipe plant based on PLC logic control, provided in an embodiment of the present invention;

[0065] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0066] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0067] This application provides a power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control. The execution entity of this PLC logic-controlled power adjustment method includes, but is not limited to, at least one of the following electronic devices that can be configured to execute the method provided in this application: a server, a terminal, etc. In other words, the PLC logic-controlled power adjustment method for a pipe threading machine in a steel pipe plant can be executed by software or hardware installed on a terminal device or a server device. The server includes, but is not limited to, a single server, a server cluster, a cloud server, or a cloud server cluster. The server can be an independent server or a cloud server that provides basic cloud computing services such as cloud services, cloud databases, cloud computing, cloud functions, cloud storage, network services, cloud communication, middleware services, domain name services, security services, content delivery networks (CDN), and big data and artificial intelligence platforms.

[0068] Reference Figure 1 The diagram shown is a flowchart illustrating a PLC logic-controlled power adjustment method for a pipe threading machine in a steel pipe plant, according to an embodiment of the present invention. In this embodiment, the PLC logic-controlled power adjustment method for a pipe threading machine in a steel pipe plant includes:

[0069] In this embodiment of the invention, A1, the real-time load current of the main drive mechanism in the tube threading machine, the real-time position data of the tube blank on the conveying roller, the real-time temperature data of the tube blank, and the real-time feedback torque of the main drive mechanism are obtained.

[0070] A high-precision current transformer is installed in series in the drive circuit of the main transmission mechanism. The current transformer senses the current change in the drive circuit in real time and converts it into an electrical signal that is linearly related to the load current. The electrical signal is transmitted to the analog input module of the programmable logic controller. The analog input module continuously acquires and converts the received electrical signal at a current sampling frequency of fifty times per second, and directly outputs the real-time load current of the main transmission mechanism.

[0071] An incremental photoelectric encoder is installed on the roller drive path of the conveyor roller. The photoelectric encoder is coaxially linked with the roller of the conveyor roller. When the roller rotates, the photoelectric encoder synchronously outputs a pulse signal and transmits the pulse signal to the high-speed counting module of the programmable logic controller. The high-speed counting module performs real-time cumulative counting of the received pulse signal. According to the preset fixed correspondence between the roller circumference and the pulse equivalent, the cumulative count value is converted into the displacement value of the tube blank on the conveyor roller and the real-time position data of the tube blank on the conveyor roller is continuously output.

[0072] Infrared temperature sensors are installed at 20-centimeter intervals along the billet conveying path on the conveying roller conveyor. The detection end of the infrared temperature sensor faces the fixed detection area on the outer surface of the billet. The infrared temperature sensor continuously detects the infrared radiation energy on the outer surface of the billet at a temperature sampling frequency of 30 times per second. The detected infrared radiation energy is converted into a voltage signal that is linearly related to the temperature. The voltage signal is transmitted to the analog input module of the programmable logic controller. The analog input module performs signal calibration and conversion on the received voltage signal and directly outputs the real-time temperature data of the billet.

[0073] A static torque sensor is installed at the output shaft end of the main drive mechanism. The static torque sensor is rigidly connected to the output shaft of the main drive mechanism. When the main drive mechanism is running, the torque change of the output shaft will cause the static torque sensor to generate a resistance change signal that is linearly related to the torque value. This resistance change signal is transmitted to the signal conditioning module. The signal conditioning module amplifies and filters the received resistance change signal and converts it into a standard electrical signal. The standard electrical signal is transmitted to the analog input module of the programmable logic controller. The analog input module performs real-time acquisition and signal conversion of the received standard electrical signal and directly outputs the real-time feedback torque of the main drive mechanism.

[0074] The beneficial effects are as follows: by configuring appropriate sensing devices for different detection data and setting fixed specifications for the installation positions and linkage methods of various devices, and by setting fixed sampling frequencies and signal conversion rules for each functional module of the programmable logic controller, accurate acquisition and stable output of real-time load current of the main drive mechanism, real-time position data of the billet on the conveyor roller, real-time temperature data of the billet, and real-time feedback torque of the main drive mechanism are achieved. The operation process of each acquisition link has clear execution standards, ensuring the real-time performance, accuracy, and consistency of the acquired data. The acquired data can accurately reflect the operating status of the main drive mechanism of the tube threading machine and the actual state of the billet, providing a reliable and reproducible data source for subsequent logic control operations such as torque dynamic correction and control signal generation by the programmable logic controller, ensuring that each link of the subsequent power adjustment of the tube threading machine can be carried out in an orderly manner based on the actual equipment and billet state.

[0075] A2. When the real-time position data reaches the preset bite start position threshold, the programmable logic controller dynamically corrects the reference torque value extracted from the historical production data based on the real-time temperature data to obtain the first target torque value of the tube threading machine.

[0076] In this embodiment of the invention, when the real-time position data reaches a preset bite start position threshold, the programmable logic controller dynamically corrects the reference torque value extracted from historical production data based on the real-time temperature data to obtain the first target torque value of the tube threading machine, including:

[0077] The programmable logic controller continuously compares the real-time position data with the preset bite start position threshold. When the real-time position data reaches the bite start position threshold, it generates a trigger signal for the tube threading machine.

[0078] In response to the trigger signal, the programmable logic controller extracts the average torque value of the steel grade information in the historical piercing process from historical production data based on the steel grade information of the billet, and uses the average torque value as the reference torque value of the tube threading machine.

[0079] Retrieve historical torque records at the same temperature as the real-time temperature data from historical production data to obtain the temperature matching torque value of the tube threading machine;

[0080] The temperature compensation amount of the tube threading machine is obtained by quantifying the difference between the temperature matching torque value and the reference torque value.

[0081] The reference torque value and temperature compensation are used to correct the calculation, and the first target torque value of the tube threading machine is obtained.

[0082] The formula for calculating the first target torque value is as follows:

[0083] ;

[0084] In the formula, The first target torque value, The reference torque value, This is the temperature compensation amount. The preset dynamic compensation coefficient, This represents the rate of temperature change.

[0085] The logic operation module of the programmable logic controller (PLC) receives real-time position data of the tube blank 50 times per second. At the same time, it retrieves a fixed value of the pre-stored bite start position threshold from its own storage module. The logic operation module compares the real-time position data value with the bite start position threshold value one by one. When the real-time position data value is exactly equal to the bite start position threshold value, the logic operation module sends a level trigger command to the signal output unit of the PLC. The signal output unit converts the command into a standard switch signal, which is the trigger signal of the tube threading machine.

[0086] After receiving the trigger signal from the tube threading machine, the signal receiving module of the programmable logic controller (PLC) immediately sends a data retrieval instruction to the internal data retrieval module. The data retrieval module first reads the billet steel grade information pre-entered in the PLC storage module, and then retrieves the torque records of all historical piercing processes corresponding to the steel grade from the historical production database with a stable data connection established with the PLC through the communication port. The numerical statistics module of the PLC sums the values ​​of all retrieved torque records, and then divides the sum by the total number of historical torque records corresponding to the steel grade. The calculated value is the average torque value of the steel grade in the historical piercing process. The PLC directly defines this average torque value as the reference torque value of the tube threading machine and stores it in the torque data storage area specified inside the PLC.

[0087] The programmable logic controller (PLC) temperature data processing module acquires the real-time temperature data of the tube blank. Using this specific value as the unique search keyword, it retrieves all historical torque records corresponding to the temperature data that is completely consistent with the value from the historical production database through the communication port. The PLC's value processing module sums the values ​​of all historical torque records of this type and then divides the sum by the total number of historical torque records of this type. The calculated value is the temperature matching torque value of the tube threading machine. The PLC stores this temperature matching torque value in the temporary data storage area inside the PLC.

[0088] The numerical calculation module of the programmable logic controller (PLC) retrieves the specific value of the reference torque value from the torque data storage area and the specific value of the temperature matching torque value from the temporary data storage area. The numerical calculation module subtracts the reference torque value from the temperature matching torque value, and the specific difference result is the difference between the quantized temperature matching torque value and the reference torque value. The PLC directly defines this specific difference result as the temperature compensation amount of the pipe threading machine and stores it in the dedicated compensation amount data storage unit inside the PLC.

[0089] The preset dynamic compensation coefficient is a fixed value determined based on historical piercing data from the steel pipe plant's long-term piercing production of all steel grades. It is combined with statistical analysis of the actual impact of the billet temperature change rate on the torque adjustment of the main drive mechanism, and then verified through multiple on-site piercing production debugging. It is pre-stored in the dedicated storage module of the programmable logic controller. The temperature change rate is obtained by the programmable logic controller continuously acquiring the real-time temperature data of the billet at a preset fixed sampling time interval, calculating the numerical difference of the real-time temperature data at two adjacent sampling time points, and then dividing the difference by the preset fixed sampling time interval.

[0090] The torque correction module of the programmable logic controller (PLC) retrieves the reference torque value from the torque data storage area, the temperature compensation value from the compensation data storage unit, and the dynamic compensation coefficient from the dedicated storage module. At the same time, it calculates the temperature change rate of the tube blank and completes the quantization calculation according to the calculation formula of the first target torque value. The final value obtained is the first target torque value of the tube threading machine. The PLC stores the first target torque value in the dedicated data area inside the PLC for torque control of the main drive mechanism, providing data support for subsequent torque adjustment operations.

[0091] The beneficial effects of this implementation process are that it sets fixed and clear execution standards for various operations of the programmable logic controller, clearly standardizes the parameter sources and calculation process of temperature compensation, temperature change rate and dynamic compensation coefficient, and completes dynamic quantitative correction of the reference torque value through formula. This ensures that the calculation of the first target torque value not only matches the torque compensation requirements corresponding to the real-time temperature of the tube blank, but also adapts to the real-time temperature change trend of the tube blank. Each link has specific operation steps and data processing methods, ensuring the reproducibility of the entire process. This allows the setting of the first target torque value to accurately match the actual properties of the tube blank and the production conditions, providing accurate and reliable target data for the subsequent torque adjustment of the main drive mechanism. This improves the pertinence and accuracy of the tube threading machine torque adjustment from the data source, ensuring that the torque preset link is highly adapted to the actual production needs.

[0092] A3. Compare the deviation between the first target torque value and the real-time feedback torque, and generate the first drive control signal of the tube threading machine based on the deviation value after comparison and send it to the main drive mechanism.

[0093] In this embodiment of the invention, the step of comparing the deviation between the first target torque value and the real-time feedback torque, and generating a first drive control signal for the tube threading machine based on the compared deviation value and sending it to the main drive mechanism, includes:

[0094] The first target torque value is mapped to the real-time feedback torque to obtain the torque deviation signal of the tube threading machine.

[0095] The torque deviation signal is input to the proportional-integral regulator in the programmable logic controller for proportional-integral analysis to obtain the initial control quantity of the pipe threading machine.

[0096] The initial control quantity is subjected to a limiting process to obtain the limited control quantity after the initial control quantity is obtained;

[0097] The control quantity after the amplitude limiting is converted from digital to analog to obtain the first drive control signal of the tube threading machine;

[0098] The first drive control signal is sent to the main drive mechanism through the analog output port of the programmable logic controller.

[0099] The numerical calculation module of the programmable logic controller (PLC) retrieves the specific value of the first target torque from the dedicated data area for torque control of the main drive mechanism, and retrieves the specific value of the real-time feedback torque of the main drive mechanism from the analog input module. The numerical calculation module performs a difference calculation on the two values ​​to obtain the torque deviation value. At the same time, the signal mapping module retrieves the numerical-electrical signal linear mapping rule pre-stored in the PLC. This rule is set based on the correspondence characteristics between the torque deviation of the main drive mechanism and the electrical signal. The signal mapping module converts the torque deviation value into the corresponding analog voltage signal according to the rule. This analog voltage signal is the torque deviation signal of the tube threading machine.

[0100] The signal transmission module of the programmable logic controller transmits the torque deviation signal to the signal input port of the internally integrated proportional-integral controller in real time. The proportional-integral controller first performs proportional processing on the torque deviation signal, amplifying the amplitude of the deviation signal by a fixed ratio according to the preset proportional adjustment rule. This rule is based on the torque adjustment response characteristics of the main drive mechanism. Then, it performs integral processing on the proportionally processed signal, continuously accumulating the signal in the time dimension to eliminate the static deviation of the signal. Finally, it combines the proportional processing result with the integral processing result to obtain the composite electrical signal, which is the initial control quantity of the pipe threading machine.

[0101] The limiting processing module of the programmable logic controller receives the initial control quantity and retrieves the pre-stored upper and lower threshold values ​​of the control quantity from its own storage unit. These two threshold values ​​are determined according to the torque adjustment limit of the main drive mechanism and the equipment operation safety specifications. The limiting processing module compares the amplitude of the initial control quantity with the upper and lower threshold values ​​respectively. If the amplitude of the initial control quantity is between the two threshold values, the initial control quantity is directly retained. If it exceeds the upper threshold value, it is corrected to the control quantity corresponding to the upper threshold value. If it exceeds the lower threshold value, it is corrected to the control quantity corresponding to the lower threshold value. The control quantity after judgment or correction is the limited control quantity of the initial control quantity.

[0102] The digital-to-analog converter module of the programmable logic controller receives the limited control quantity. This digital-to-analog converter module is a hardware conversion module that processes the digital signal of the limited control quantity at a fixed conversion frequency and converts it into a standard analog current signal that matches the signal type of the drive interface of the main drive mechanism. This standard analog current signal is the first drive control signal of the tube threading machine.

[0103] The analog output port of the programmable logic controller receives the first drive control signal output by the digital-to-analog converter module. This port is an industrial-grade dedicated output port. First, the first drive control signal is subjected to anti-interference filtering to eliminate noise in the signal transmission. Then, the signal is amplified to the signal amplitude range that can be recognized by the torque control receiver of the main drive mechanism. Subsequently, the processed first drive control signal is transmitted to the torque control receiver of the main drive mechanism in real time and without attenuation through a shielded communication cable, thus completing the transmission operation of the first drive control signal.

[0104] The beneficial effects of this implementation process are that it establishes a fixed execution standard for the generation and transmission of the first drive control signal. Each step relies on the dedicated hardware module of the programmable logic controller to complete the operation. It clarifies the rules of deviation mapping, the specific process of proportional-integral adjustment, the judgment criteria for amplitude limiting, and the specific methods of signal conversion and transmission. The unambiguous processing steps ensure the reproducibility of the process. Proportional-integral adjustment eliminates the static deviation of torque deviation, amplitude limiting avoids equipment damage to the main drive mechanism caused by over-range control, and the processing of signal conversion and transmission ensures the stability and effectiveness of the first drive control signal. The generated first drive control signal can accurately match the torque adjustment requirements of the main drive mechanism, realize closed-loop control of torque deviation during the biting stage, improve the real-time performance and accuracy of torque adjustment of the main drive mechanism, and ensure the stable operation of power adjustment during the biting stage of the tube threading machine.

[0105] A4. After the main drive mechanism bites into the tube blank, the programmable logic controller identifies the waveform of the continuously acquired real-time load current to obtain the status signal of the tube threading machine.

[0106] In this embodiment of the invention, after the main drive mechanism bites into the tube blank, the programmable logic controller performs waveform identification on the continuously acquired real-time load current to obtain the status signal of the tube threading machine, including:

[0107] After the main drive mechanism completes the biting action on the tube blank, the programmable logic controller performs waveform truncation on the continuously acquired real-time load current to obtain a current waveform segment of the real-time load current.

[0108] Time-domain features are extracted from the current waveform segment to obtain the waveform rise rate, peak waveform amplitude, and waveform oscillation period of the current waveform segment;

[0109] Based on the waveform rise rate and peak waveform amplitude, the impact load characteristics borne by the main drive mechanism during the billet biting process are analyzed to obtain the biting impact characteristics of the billet.

[0110] Based on the waveform fluctuation period, the fluctuation pattern of the current waveform segment is mined to obtain the fluctuation pattern recognition result of the current waveform segment.

[0111] The bite impact characteristics and fluctuation pattern recognition results are logically combined to obtain the status signal of the tube insertion machine.

[0112] The programmable logic controller (PLC) determines the completion of the biting action by detecting the torque data of the main drive mechanism. When the real-time feedback torque of the main drive mechanism is stably maintained within the preset torque stability range and the duration reaches the preset judgment duration, the blank biting action is determined to be completed. Subsequently, the PLC's waveform capture module continuously acquires the electrical signal data of the real-time load current from the analog input module. The PLC captures the continuous current signal data according to the pre-stored fixed time length, integrates and stores all the current signal data within the capture time period in chronological order, and the resulting continuous current signal waveform is the current waveform segment of the real-time load current.

[0113] The time-domain feature extraction module of the programmable logic controller retrieves the stored current waveform segment, collects the waveform segment point by point, records the current amplitude data and corresponding time data at each collection point, calculates the correlation between the total change in current amplitude and the total change in time during the waveform rise phase, and obtains the waveform rise rate of the current waveform segment. It iterates through the current amplitude data of all collection points of the waveform segment, selects the maximum value as the peak value of the current waveform segment, and counts the time interval between two adjacent peaks or two adjacent troughs in the waveform segment. All the counted time intervals are integrated and processed to obtain the waveform fluctuation period of the current waveform segment.

[0114] The impact load analysis module of the programmable logic controller retrieves the waveform rise rate and peak waveform amplitude, and simultaneously retrieves the pre-stored load feature association table from the storage module. This table is established based on the historical load test data of the steel pipe plant's pipe threading production and the equipment load characteristics of the main drive mechanism. It contains a fixed correspondence between the waveform rise rate, peak waveform amplitude and the type and intensity of the impact load. The two extracted time-domain features are precisely matched with the load feature association table to obtain the corresponding impact load information of the main drive mechanism. This information is then structured and integrated to form complete load feature data, which is the bite impact feature of the billet.

[0115] The fluctuation pattern mining module of the programmable logic controller retrieves the waveform fluctuation period of the extracted current waveform segment, continuously counts all fluctuation periods within the waveform segment, determines the continuous change state of the fluctuation period, and retrieves the pre-stored fluctuation pattern judgment rules from the storage module. These rules are established based on the correlation between real-time load current fluctuation and the operating state of the main drive mechanism. According to the statistical results of the fluctuation period, the corresponding fluctuation uniformity, fluctuation duration characteristics and other pattern information are matched. These pattern information are systematically sorted out, and the complete fluctuation pattern judgment data formed is the fluctuation pattern recognition result of the current waveform segment.

[0116] The logic combination module of the programmable logic controller retrieves the bite impact characteristics of the tube blank from the impact load analysis module, retrieves the fluctuation pattern recognition results of the current waveform segment from the fluctuation law mining module, and retrieves the pre-stored logic combination rules from the storage module. These rules are established based on the generation requirements of the tube threading machine's operating status signal. According to the rules, the key data of the bite impact characteristics and fluctuation pattern recognition results are structurally fused, and the fused feature data is converted into a standard electrical signal that the PLC can recognize. This standard electrical signal is the status signal of the tube threading machine, and then the status signal is transmitted to the PLC's operating status determination module.

[0117] The beneficial effects of this implementation process are that it establishes clear and fixed execution standards for the generation of status signals of the tube threading machine, clarifies the judgment criteria for the tube blank biting action, the method for extracting current waveform segments, and the specific extraction method for time-domain features. Based on pre-stored association tables and judgment rules, it completes the impact load feature analysis and fluctuation law mining. The rule setting of the logic combination link ensures the rationality of feature data fusion. Each link is completed through the dedicated hardware module of the PLC, with no fuzzy processing steps, ensuring the reproducibility of the entire process. The extracted time-domain features can accurately capture the key changes in real-time load current. The analyzed biting impact features and fluctuation pattern recognition results can truly reflect the actual operating state of the main drive mechanism. The status signals generated after logic combination provide reliable and accurate signal basis for the accurate judgment of the stable piercing stage of the tube threading machine, improving the real-time performance and accuracy of the tube threading machine's operating status identification, and laying a solid foundation for the subsequent dynamic composite adjustment in the stable piercing stage.

[0118] A5. When the status signal indicates that the piercing stage has been entered, analyze the coupling relationship between the fluctuation mode of the real-time load current and the real-time temperature data to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjust the conveying speed of the conveying roller and the second target torque value of the main drive mechanism according to the speed-torque composite adjustment coefficient.

[0119] In this embodiment of the invention, when the status signal indicates that the piercing stage has been entered, analyzing the coupling relationship between the fluctuation pattern of the real-time load current and the real-time temperature data to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjusting the conveying speed of the conveyor roller and the second target torque value of the main drive mechanism according to the speed-torque composite adjustment coefficient, includes:

[0120] When the status signal indicates that the pipe-piercing machine has entered the stable piercing stage, the programmable logic controller analyzes the fluctuation cycle of the continuously acquired real-time load current to obtain the fluctuation pattern of the real-time load current.

[0121] Temperature change trend analysis was performed on the real-time temperature data continuously acquired during the stable piercing stage to obtain the temperature gradient characteristics and average temperature characteristics of the tube blank during the piercing process.

[0122] The correlation between the fluctuation mode and the temperature gradient characteristics and the average temperature characteristics is determined to obtain the coupling relationship between the real-time load current and the tube blank.

[0123] Based on the coupling relationship and the deviation between the current fluctuation range of the real-time load current and the reference fluctuation range in the historical production data, the torque adjustment amount of the main drive mechanism and the speed adjustment amount of the conveyor roller are calculated to obtain the speed-torque composite adjustment coefficient of the tube threading machine.

[0124] Based on the speed-torque composite adjustment coefficient, the torque value of the main drive mechanism is corrected before the start of the stable piercing stage to obtain the second target torque value of the main drive mechanism.

[0125] Based on the speed-torque composite adjustment coefficient, the initial conveying speed of the conveyor rollers is dynamically compensated before the start of the stable piercing stage to obtain the adjusted conveying speed of the conveyor rollers.

[0126] The step of determining the correlation between the fluctuation mode and temperature gradient characteristics and temperature mean characteristics to obtain the coupling relationship between the real-time load current and the tube blank includes:

[0127] By time-registering the fluctuation pattern with temperature gradient characteristics and temperature mean characteristics, a current-temperature correlation data pair between real-time load current and tube blank is constructed.

[0128] Response identification is performed on current-temperature correlation data pairs to obtain the response characteristics of current-temperature correlation data;

[0129] Based on the response characteristics, the coupling relationship between the real-time load current and the tube blank is generated.

[0130] The formula for calculating the speed-torque composite adjustment coefficient is as follows:

[0131] ;

[0132] This is the speed-torque composite adjustment coefficient. The preset base adjustment coefficient, This represents the current fluctuation range. For reference fluctuation range, This represents the coupling strength coefficient extracted from the coupling relationship. It is a temperature gradient feature. The temperature average characteristic is... The fluctuation frequency of the real-time load current extracted from the fluctuation mode.

[0133] After receiving the status signal indicating that the pipe-piercing machine has entered the stable piercing stage, the programmable logic controller's operating status determination module immediately sends an analysis command to the fluctuation analysis module. The fluctuation analysis module continuously acquires real-time load current data of the main drive mechanism from the analog input module at a fixed sampling frequency. It identifies and marks the peaks and troughs of the continuous current data, counts the time intervals between adjacent peaks and troughs, integrates all interval data, analyzes the variation characteristics and distribution of the interval data, defines the integrated and analyzed current cycle variation characteristic data as the fluctuation mode of the real-time load current, and stores it in the designated data area. At the same time, it extracts the number of times the current peak occurs per unit time from this fluctuation mode to complete the numerical quantization and obtain the fluctuation frequency of the real-time load current.

[0134] After the tube threading machine enters the stable piercing stage, the temperature trend analysis module of the programmable logic controller continuously acquires the real-time temperature data of the tube blank from the temperature data processing module. It performs segmented statistical analysis on the real-time temperature data according to a preset fixed time window, calculates the average value of all temperature data in each time window, and integrates the average values ​​of all time windows to form the characteristic data of the tube blank during the piercing process. At the same time, it calculates the correlation between the change in the average temperature value of two adjacent time windows and the time window interval, and integrates the characteristic data of the correlation to form the temperature gradient characteristic of the tube blank during the piercing process. Both are stored in the temperature characteristic data area after numerical quantization.

[0135] The time registration module of the programmable logic controller retrieves the fluctuation pattern data of the real-time load current from the specified data area, and retrieves the temperature gradient characteristic and temperature mean characteristic data of the tube blank from the temperature trend analysis module. It adds a timestamp with uniform time precision to the fluctuation pattern data, temperature gradient characteristic data, and temperature mean characteristic data. According to the order of the timestamps, the fluctuation pattern data corresponding to the same time node is matched one by one with the temperature gradient characteristic and temperature mean characteristic data. The three types of data that are successfully matched are structured and integrated. Each set of integrated data is the current-temperature correlation data pair between the real-time load current and the tube blank.

[0136] The response identification module of the programmable logic controller retrieves all the completed current-temperature correlation data pairs and arranges them in the order of timestamps. It analyzes the time lag state and synchronous state of the fluctuation mode of the real-time load current as the characteristics of the billet temperature gradient and the temperature mean characteristics change. At the same time, it identifies the correlation state between the fluctuation mode change amplitude and the temperature characteristic change amplitude. It systematically sorts out these identified state data, and the sorted complete state characteristic data is the response characteristics of the current-temperature correlation data.

[0137] The coupling relationship generation module of the programmable logic controller retrieves the response characteristics of the current-temperature correlation data. At the same time, it retrieves the pre-stored coupling relationship judgment table from the storage module. This judgment table is established based on the historical process data and equipment operation data of the steel pipe plant's pipe-laying production. It contains fixed correspondence information between response characteristics and coupling relationships. The key data of the response characteristics are accurately matched with the coupling relationship judgment table. The matched correlation type, correlation strength and other information are extracted and structured and integrated. The integrated complete correlation information is the coupling relationship between the real-time load current and the billet. At the same time, the correlation strength level is extracted from the coupling relationship to complete the numerical conversion and obtain the coupling strength coefficient.

[0138] The programmable logic controller's (PLC) ratio calculation module first retrieves the real-time load current fluctuation pattern data and calculates the current fluctuation amplitude of the real-time load current. Then, it retrieves the real-time load current reference fluctuation amplitude under the same steel grade and piercing conditions from the historical production database through the communication port. At the same time, it retrieves the preset basic adjustment coefficient from the dedicated storage module, which is determined after statistical analysis of historical production data during the stable piercing stage of all steel grades and verification through on-site debugging. Subsequently, it retrieves the coupling strength coefficient, temperature gradient characteristics, temperature mean characteristics, and fluctuation frequency, and completes the full-dimensional quantitative calculation according to the calculation formula of the speed-torque composite adjustment coefficient. The comprehensive adjustment parameter obtained by the calculation is the speed-torque composite adjustment coefficient of the tube threading machine.

[0139] Before the pipe threading machine begins its stable piercing phase, the torque correction module of the programmable logic controller retrieves the initial torque value of the main drive mechanism from its dedicated torque control data area for the stable piercing phase. At the same time, it retrieves the speed-torque composite adjustment coefficient of the pipe threading machine. According to the pre-stored torque correction rules, the initial torque value is numerically corrected based on the speed-torque composite adjustment coefficient. The torque value obtained after correction is the second target torque value of the main drive mechanism, and this value is stored in the dedicated torque control data area.

[0140] Before the tube threading machine reaches the stable piercing stage, the speed compensation module of the programmable logic controller retrieves the initial conveying speed value of the conveyor roller control module during the stable piercing stage. At the same time, it retrieves the speed-torque composite adjustment coefficient of the tube threading machine. According to the pre-stored speed compensation rules, the initial conveying speed value is dynamically compensated based on the speed-torque composite adjustment coefficient. The speed value obtained after dynamic compensation is the adjusted conveying speed of the conveyor roller, and this value is stored in the dedicated data area of ​​the roller control.

[0141] The beneficial effects of this implementation process are that it establishes a fixed and reproducible execution standard for the preliminary data processing and parameter setting of speed-torque composite regulation in the stable piercing stage. It clarifies the extraction and analysis methods for fluctuation patterns and temperature characteristics, as well as the construction logic for current-temperature correlation data pairs. Relying on pre-stored judgment tables and rules, it completes response identification and coupling relationship generation. Simultaneously, it clarifies the extraction, quantification, and acquisition process of each parameter in the speed-torque composite regulation coefficient calculation formula. Through the formula, it organically quantifies and integrates the basic regulation coefficient, current fluctuation characteristics, billet temperature characteristics, and their coupling relationship, allowing the calculation of the composite regulation coefficient to take into account multiple dimensions. Due to the influence of production conditions, each step is completed through a dedicated hardware module of the programmable logic controller, without any fuzzy processing steps. This ensures the accuracy of all parameters and characteristic data. The corrected and compensated second target torque value and the adjusted conveying speed are highly adaptable to the production conditions of the stable piercing stage. This provides accurate and reliable parameter basis for the power coordination adjustment in the subsequent stable piercing stage, improving the coordination and adaptability of the power adjustment in the stable piercing stage of the tube threading machine. At the same time, it gives the calculation process of the speed-torque composite adjustment coefficient a clear quantitative standard, further ensuring the operability and reproducibility of the entire adjustment process.

[0142] A6. During the stable piercing stage, the continuously acquired real-time feedback torque is compared with the second target torque value to determine the deviation. Based on the determined deviation value, a second drive control signal for the tube piercing machine is generated and sent to the main drive mechanism to adjust the output torque of the main drive mechanism in real time.

[0143] In this embodiment of the invention, during the stable piercing stage, the deviation between the continuously acquired real-time feedback torque and the second target torque value is determined, and based on the determined deviation value, a second drive control signal for the tube-piercing machine is generated and sent to the main drive mechanism to adjust the output torque of the main drive mechanism in real time, including:

[0144] During the stable piercing stage, the programmable logic controller quantifies the deviation between the continuously acquired real-time feedback torque and the second target torque value to obtain the torque tracking deviation value of the piercing machine.

[0145] The torque tracking deviation value is input to the proportional-integral regulator in the programmable logic controller for control quantity tuning, so as to obtain the torque correction amount after the pipe threading machine is limited;

[0146] The torque correction amount after limiting is algebraically added to the second target torque value to obtain the third target torque value of the pipe threading machine;

[0147] The third target torque value is mapped to the drive signal to obtain the second drive control signal of the pipe threading machine;

[0148] The second drive control signal is sent to the main drive mechanism through the analog output port of the programmable logic controller to track and adjust the output torque of the main drive mechanism in real time.

[0149] During the stable piercing stage, the numerical calculation module of the programmable logic controller retrieves the specific value of the second target torque from the dedicated data area for torque control of the main drive mechanism at a fixed sampling frequency. At the same time, it retrieves the specific value of the real-time feedback torque of the main drive mechanism from the analog input module. The numerical calculation module performs a difference calculation between the second target torque value and the real-time feedback torque at the same sampling time node, and performs numerical quantization processing on the calculated difference result. The specific difference value after quantization is the torque tracking deviation value of the piercing machine, and this value is transmitted to the torque adjustment module of the PLC in real time.

[0150] The programmable logic controller (PLC) signal transmission module transmits the torque tracking deviation value to the signal input port of the internally integrated proportional-integral (PI) controller in real time. The PI controller first performs proportional processing on the torque tracking deviation value, amplifying the deviation value by a fixed ratio according to the pre-stored proportional adjustment rules. These rules are determined through on-site debugging based on the torque adjustment response characteristics of the main drive mechanism during the stable piercing stage. Then, it performs integral processing on the proportionally processed value, continuously accumulating the value over time to eliminate the static deviation of the torque deviation. After the calculation, a preliminary torque correction amount is obtained. The PLC's limiting processing module then retrieves the pre-stored upper and lower threshold values ​​for the torque correction amount. These threshold values ​​are set according to the torque adjustment limits of the main drive mechanism and the equipment's operational safety regulations. The limiting processing module compares the preliminary torque correction amount with the two threshold values ​​respectively. If it exceeds the threshold, it is corrected to the corresponding threshold value; otherwise, it is directly retained. The processed value is the torque correction amount after limiting by the piercing machine.

[0151] The numerical calculation module of the programmable logic controller retrieves the specific value of the torque correction after the limit is obtained from the torque adjustment module, and retrieves the specific value of the second target torque value from the dedicated data area for torque control of the main drive mechanism. The numerical calculation module performs algebraic addition on the two values ​​and stores the calculated comprehensive torque value in the temporary torque control data area inside the PLC. This comprehensive torque value is the third target torque value of the pipe threading machine.

[0152] The signal mapping module of the programmable logic controller retrieves the specific value of the third target torque from the temporary torque control data area, and at the same time retrieves the torque-electric signal linear mapping rule pre-stored in the PLC storage module. This rule is based on the correspondence characteristics between the torque output of the main drive mechanism and the drive signal, and is established in combination with the on-site debugging data of the steel pipe threading production. The signal mapping module converts the specific value of the third target torque into a standard analog electrical signal that matches the signal type of the drive interface of the main drive mechanism according to the rule. This standard analog electrical signal is the second drive control signal of the pipe threading machine.

[0153] The analog output port of the programmable logic controller receives the second drive control signal transmitted by the signal mapping module. This port first performs anti-interference filtering on the second drive control signal through a hardware filtering circuit to eliminate noise interference generated during signal transmission. Then, the amplitude of the filtered signal is amplified to a fixed signal amplitude range that can be recognized by the torque control receiver of the main drive mechanism. Subsequently, the processed second drive control signal is transmitted to the torque control receiver port of the main drive mechanism in real time and without attenuation through an industrial-grade shielded communication cable, thus completing the transmission operation of the second drive control signal. The main drive mechanism adjusts its output torque value in real time according to the received signal.

[0154] The beneficial effects of this implementation process are that it establishes a complete and reproducible execution standard for real-time tracking and adjustment of the torque of the main drive mechanism during the stable piercing stage. It clarifies the quantification method of torque tracking deviation, the specific tuning process of the proportional-integral (PI) regulator, and the judgment basis for amplitude limiting. Simultaneously, it standardizes the calculation logic of the third target torque value and the mapping and transmission process of the second drive control signal. Each step relies on the dedicated hardware module of the programmable logic controller (PLC) to complete the operation, eliminating ambiguous processing steps. The PI regulation effectively eliminates static torque deviation, amplitude limiting avoids equipment damage to the main drive mechanism caused by over-range correction, and the signal mapping and transmission ensures the stability and effectiveness of the second drive control signal. The third target torque value can be dynamically updated based on real-time torque feedback, achieving precise real-time tracking and adjustment of the main drive mechanism's output torque. This ensures that the output torque of the main drive mechanism is always adapted to the production conditions, significantly improving the real-time performance and accuracy of torque adjustment during the stable piercing stage, guaranteeing the operational stability of the pipe piercing machine during the stable piercing process, and further optimizing the processing effect of steel pipe piercing.

[0155] like Figure 2 The diagram shown is a functional block diagram of a power adjustment system for a steel pipe factory pipe threading machine based on PLC logic control, provided by an embodiment of the present invention.

[0156] The PLC-based logic control power adjustment system 100 for a steel pipe threading machine in a steel pipe plant, as described in this invention, can be installed in an electronic device. Depending on the functions implemented, the PLC-based logic control power adjustment system 100 may include a data acquisition module 101, a pre-bite torque pre-setting module 102, a pre-bite torque closed-loop control module 103, a bite state identification module 104, a stable phase coupling adjustment module 105, and a stable phase torque tracking control module 106. The module described in this invention can also be called a unit, referring to a series of computer program segments that can be executed by the processor of an electronic device and perform a fixed function, stored in the memory of the electronic device.

[0157] In this embodiment, the functions of each module / unit are as follows:

[0158] The data acquisition module 101 is used to acquire the real-time load current of the main drive mechanism in the tube threading machine, the real-time position data of the tube blank on the conveying roller, the real-time temperature data of the tube blank, and the real-time feedback torque of the main drive mechanism.

[0159] The pre-biting torque preset module 102 is used to dynamically correct the reference torque value extracted from historical production data based on real-time temperature data when the real-time position data reaches the preset biting start position threshold, so as to obtain the first target torque value of the tube threading machine.

[0160] The pre-bite torque closed-loop control module 103 is used to compare the deviation between the first target torque value and the real-time feedback torque, and generate the first drive control signal of the tube threading machine based on the deviation value after comparison and send it to the main drive mechanism.

[0161] The bite status identification module 104 is used to identify the waveform of the continuously acquired real-time load current after the main drive mechanism bites the tube blank, and obtain the status signal of the tube threading machine.

[0162] The stable phase coupling adjustment module 105 is used to analyze the coupling relationship between the fluctuation mode of the real-time load current and the real-time temperature data when the status signal indicates that the stable piercing phase has been entered, so as to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjust the conveying speed of the conveying roller and the second target torque value of the main drive mechanism according to the speed-torque composite adjustment coefficient.

[0163] The torque tracking control module 106 in the stable phase is used to determine the deviation between the continuously acquired real-time feedback torque and the second target torque value in the stable piercing phase, and generate a second drive control signal for the tube piercing machine based on the determined deviation value and send it to the main drive mechanism to adjust the output torque of the main drive mechanism in real time.

[0164] As can be seen from several embodiments of the present invention, the reference information generation method and system disclosed herein can be implemented in other forms. For example, the foregoing system embodiments are only illustrative, and the module division therein is only a division method based on logical functions. In actual implementation, other module division forms can be adopted according to requirements.

[0165] Modules described as independent components are not necessarily physically separate structures; components presented in modular form are not necessarily independent physical units, and can be centrally deployed in the same physical location or distributed across multiple network units. Those skilled in the art can select some or all of the modules to achieve the technical objectives of this embodiment based on actual application requirements.

[0166] Furthermore, the functional modules in the various embodiments of the present invention can be integrated into the same processing unit, exist independently as physical units, or integrate two or more units into a single unit. The integrated unit can implement its functions either purely in hardware or by combining hardware and software functional modules.

[0167] It will be apparent to those skilled in the art that the present invention is not limited to the specific details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the core spirit and basic characteristics of the present invention.

[0168] This application embodiment can rely on artificial intelligence technology to complete the acquisition and processing of relevant data. Artificial intelligence refers to the general term for theories, methods, technologies, and application systems that use digital computers, or intelligent machines controlled by digital computers, to simulate, extend, and expand human intelligence, thereby achieving environmental perception, knowledge acquisition, and the application of knowledge to obtain optimal results.

[0169] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or adjusted by equivalent substitution, and any modification or substitution shall not depart from the spirit and protection scope of the technical solutions of the present invention.

Claims

1. A power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control, characterized in that, The method includes: A1. Obtain the real-time load current of the main drive mechanism in the tube threading machine, the real-time position data of the tube blank on the conveyor roller, the real-time temperature data of the tube blank, and the real-time feedback torque of the main drive mechanism. A2. When the real-time position data reaches the preset bite start position threshold, the programmable logic controller dynamically corrects the reference torque value extracted from the historical production data based on the real-time temperature data to obtain the first target torque value of the tube threading machine. A3. Compare the deviation between the first target torque value and the real-time feedback torque, and generate the first drive control signal of the tube threading machine based on the deviation value after comparison and send it to the main drive mechanism. A4. After the main drive mechanism bites into the tube blank, the programmable logic controller identifies the waveform of the continuously acquired real-time load current to obtain the status signal of the tube threading machine. A5. When the status signal indicates that the piercing stage has been entered, analyze the coupling relationship between the fluctuation mode of the real-time load current and the real-time temperature data to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjust the conveying speed of the conveying roller and the second target torque value of the main drive mechanism according to the speed-torque composite adjustment coefficient. A6. During the stable piercing stage, the continuously acquired real-time feedback torque is compared with the second target torque value to determine the deviation. Based on the determined deviation value, a second drive control signal for the tube piercing machine is generated and sent to the main drive mechanism to adjust the output torque of the main drive mechanism in real time.

2. The power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control as described in claim 1, characterized in that, When the real-time position data reaches the preset bite start position threshold, the programmable logic controller dynamically corrects the reference torque value extracted from historical production data based on the real-time temperature data to obtain the first target torque value of the tube threading machine, including: The programmable logic controller continuously compares the real-time position data with the preset bite start position threshold. When the real-time position data reaches the bite start position threshold, it generates a trigger signal for the tube threading machine. In response to the trigger signal, the programmable logic controller extracts the average torque value of the steel grade information in the historical piercing process from historical production data based on the steel grade information of the billet, and uses the average torque value as the reference torque value of the tube threading machine. Retrieve historical torque records at the same temperature as the real-time temperature data from historical production data to obtain the temperature matching torque value of the tube threading machine; The temperature compensation amount of the tube threading machine is obtained by quantifying the difference between the temperature matching torque value and the reference torque value. The reference torque value and temperature compensation are used to correct the calculation, and the first target torque value of the tube threading machine is obtained.

3. The power adjustment method for a steel pipe threading machine based on PLC logic control as described in claim 2, characterized in that, The formula for calculating the first target torque value is as follows: ； In the formula, The first target torque value, The reference torque value, This is the temperature compensation amount. The preset dynamic compensation coefficient, This represents the rate of temperature change.

4. The power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control as described in claim 1, characterized in that, The step of comparing the deviation between the first target torque value and the real-time feedback torque, and generating a first drive control signal for the tube threading machine based on the compared deviation value and sending it to the main drive mechanism, includes: The first target torque value is mapped to the real-time feedback torque to obtain the torque deviation signal of the tube threading machine. The torque deviation signal is input to the proportional-integral regulator in the programmable logic controller for proportional-integral analysis to obtain the initial control quantity of the pipe threading machine. The initial control quantity is subjected to a limiting process to obtain the limited control quantity after the initial control quantity is obtained; The control quantity after the amplitude limiting is converted from digital to analog to obtain the first drive control signal of the tube threading machine; The first drive control signal is sent to the main drive mechanism through the analog output port of the programmable logic controller.

5. The power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control as described in claim 1, characterized in that, After the main drive mechanism bites into the tube blank, the programmable logic controller (PLC) performs waveform identification on the continuously acquired real-time load current to obtain the status signal of the tube threading machine, including: After the main drive mechanism completes the biting action on the tube blank, the programmable logic controller performs waveform truncation on the continuously acquired real-time load current to obtain a current waveform segment of the real-time load current. Time-domain features are extracted from the current waveform segment to obtain the waveform rise rate, peak waveform amplitude, and waveform oscillation period of the current waveform segment; Based on the waveform rise rate and peak waveform amplitude, the impact load characteristics borne by the main drive mechanism during the billet biting process are analyzed to obtain the biting impact characteristics of the billet. Based on the waveform fluctuation period, the fluctuation pattern of the current waveform segment is mined to obtain the fluctuation pattern recognition result of the current waveform segment. The bite impact characteristics and fluctuation pattern recognition results are logically combined to obtain the status signal of the tube insertion machine.

6. The power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control as described in claim 1, characterized in that, When the status signal indicates that the piercing stage has been reached, the coupling relationship between the fluctuation pattern of the real-time load current and the real-time temperature data is analyzed to obtain the speed-torque composite adjustment coefficient of the piercing machine. Based on this speed-torque composite adjustment coefficient, the conveying speed of the conveyor rollers and the second target torque value of the main drive mechanism are adjusted, including: When the status signal indicates that the pipe-piercing machine has entered the stable piercing stage, the programmable logic controller analyzes the fluctuation cycle of the continuously acquired real-time load current to obtain the fluctuation pattern of the real-time load current. Temperature change trend analysis was performed on the real-time temperature data continuously acquired during the stable piercing stage to obtain the temperature gradient characteristics and average temperature characteristics of the tube blank during the piercing process. The correlation between the fluctuation mode and the temperature gradient characteristics and the average temperature characteristics is determined to obtain the coupling relationship between the real-time load current and the tube blank. Based on the coupling relationship and the deviation between the current fluctuation range of the real-time load current and the reference fluctuation range in the historical production data, the torque adjustment amount of the main drive mechanism and the speed adjustment amount of the conveyor roller are calculated to obtain the speed-torque composite adjustment coefficient of the tube threading machine. Based on the speed-torque composite adjustment coefficient, the torque value of the main drive mechanism is corrected before the start of the stable piercing stage to obtain the second target torque value of the main drive mechanism. Based on the speed-torque composite adjustment coefficient, the initial conveying speed of the conveyor rollers is dynamically compensated before the start of the stable piercing stage to obtain the adjusted conveying speed of the conveyor rollers.

7. The power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control as described in claim 6, characterized in that, The step of determining the correlation between the fluctuation mode and temperature gradient characteristics and temperature mean characteristics to obtain the coupling relationship between the real-time load current and the tube blank includes: By time-registering the fluctuation pattern with temperature gradient characteristics and temperature mean characteristics, a current-temperature correlation data pair between real-time load current and tube blank is constructed. Response identification is performed on current-temperature correlation data pairs to obtain the response characteristics of current-temperature correlation data; Based on the response characteristics, the coupling relationship between the real-time load current and the tube blank is generated.

8. The power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control as described in claim 6, characterized in that, The formula for calculating the speed-torque composite adjustment coefficient is as follows: ； This is the speed-torque composite adjustment coefficient. The preset base adjustment coefficient, This represents the current fluctuation range. For reference fluctuation range, This represents the coupling strength coefficient extracted from the coupling relationship. It is a temperature gradient feature. The temperature average characteristic is... The fluctuation frequency of the real-time load current extracted from the fluctuation mode.

9. The power adjustment method for a pipe threading machine in a steel pipe plant based on PLC logic control as described in claim 1, characterized in that, During the stable piercing stage, the continuously acquired real-time feedback torque is compared with the second target torque value to determine the deviation. Based on the determined deviation value, a second drive control signal for the piercing machine is generated and sent to the main drive mechanism to adjust the output torque of the main drive mechanism in real time, including: During the stable piercing stage, the programmable logic controller quantifies the deviation between the continuously acquired real-time feedback torque and the second target torque value to obtain the torque tracking deviation value of the piercing machine. The torque tracking deviation value is input to the proportional-integral regulator in the programmable logic controller for control quantity tuning, so as to obtain the torque correction amount after the pipe threading machine is limited; The torque correction amount after limiting is algebraically added to the second target torque value to obtain the third target torque value of the pipe threading machine; The third target torque value is mapped to the drive signal to obtain the second drive control signal of the pipe threading machine; The second drive control signal is sent to the main drive mechanism through the analog output port of the programmable logic controller to track and adjust the output torque of the main drive mechanism in real time.

10. A power adjustment system for a pipe threading machine in a steel pipe plant based on PLC logic control, characterized in that, The system is used to implement the power adjustment method for a steel pipe threading machine based on PLC logic control as described in claim 1, the system comprising: The data acquisition module is used to acquire the real-time load current of the main drive mechanism in the tube threading machine, the real-time position data of the tube blank on the conveying roller, the real-time temperature data of the tube blank, and the real-time feedback torque of the main drive mechanism. The pre-biting torque preset module is used to dynamically correct the reference torque value extracted from historical production data based on real-time temperature data when the real-time position data reaches the preset biting start position threshold, so as to obtain the first target torque value of the tube threading machine. The pre-bite torque closed-loop control module is used to compare the deviation between the first target torque value and the real-time feedback torque, and generate the first drive control signal of the tube threading machine based on the deviation value after comparison and send it to the main drive mechanism. The bite status identification module is used to identify the waveform of the continuously acquired real-time load current after the main drive mechanism bites the tube blank, and obtain the status signal of the tube threading machine. The stable phase coupling adjustment module is used to analyze the coupling relationship between the fluctuation mode of the real-time load current and the real-time temperature data when the status signal indicates that the piercing stage has been entered, so as to obtain the speed-torque composite adjustment coefficient of the piercing machine, and adjust the conveying speed of the conveying roller and the second target torque value of the main drive mechanism according to the speed-torque composite adjustment coefficient. The torque tracking control module in the stable phase is used to determine the deviation between the continuously acquired real-time feedback torque and the second target torque value during the stable piercing phase. Based on the determined deviation value, it generates a second drive control signal for the tube piercing machine and sends it to the main drive mechanism to adjust the output torque of the main drive mechanism in real time.

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