Automatic winding device and control method

Abstract

The present invention proposes an automatic coiling device and control method, wherein the coiling device includes a coil trolley and a PLC, and also includes a laser distance measuring device located beside the core shaft; the coil trolley places the coil horizontally with a liftable saddle and controls the vertical position of the coil; the travel path of the coil trolley, the core shaft, and the center axis of the coil are parallel to each other and located in the same vertical working plane; a photoelectric beam switch group is provided at the travel path of the coil trolley; the PLC detects the specifications of the coil by means of the photoelectric beam switch group and the laser distance measuring device, measures the distance between the coil trolley and the core shaft by means of the laser distance measuring device, and controls the coil trolley to automatically insert the coil into the core shaft; the present invention can utilize a combination of devices such as the photoelectric beam switch and the laser distance measuring device, combined with mathematical logic operations and control the height of the coil lifted by the trolley and the distance the coil is transported, and directly transport the coil to the center of the core shaft by the trolley.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum material processing, in particular to an automatic coiling device and a control method. Background Art

[0002] When processing coils, traditional coil loading is manual, and the coil needs to be loaded onto the exact center of the core shaft, that is, the coil trolley is manually controlled to rise and fall and move back and forth. On the one hand, this is inefficient, and on the other hand, it is limited by the operator's skills, and there is a risk of bumping and tilting the coil.

[0003] The present invention can upgrade the rolling method from manual to automatic, thereby improving efficiency and reducing risks. Summary of the Invention

[0004] The present invention proposes an automatic coiling device and control method, which can utilize a combination of devices such as a photoelectric beam switch and a laser distance measuring device, combined with mathematical logic operations to control the height of the coil lifted by a trolley and the distance the coil is transported, and directly transport the coil to the center of the core shaft through the trolley.

[0005] The present invention adopts the following technical solutions.

[0006] An automatic coiling device comprises a coil trolley and a programmable logic controller (PLC), and further comprises a laser distance measuring device located beside a core shaft; the coil trolley places the coil horizontally on a liftable saddle and controls the vertical position of the coil; the travel path of the coil trolley, the core shaft, and the center axis of the coil are parallel to each other and located in the same vertical working plane; a photoelectric beam switch group is provided on the travel path of the coil trolley; the PLC detects the specifications of the coil by means of the photoelectric beam switch group and the laser distance measuring device, measures the distance between the coil trolley and the core shaft by means of the laser distance measuring device, and controls the coil trolley to automatically insert the coil onto the core shaft.

[0007] The coiled material is a rolled body formed by winding a thin material on a sleeve; the length of the sleeve is not less than the width of the thin material; the length of the core shaft is not less than the length of the sleeve.

[0008] The photoelectric beam switch group includes a first photoelectric beam switch located at the starting point of the coil trolley's travel path, and also includes a second photoelectric beam switch located at the coil trolley's travel path; the detection directions of the first photoelectric beam switch and the second photoelectric beam switch are perpendicular to the travel path, the core shaft, and the working surface where the coil center axis is located;

[0009] When the saddle places the coil horizontally and the saddle is at the lowest point, the first photoelectric shooting switch is located above the coil;

[0010] When the coil trolley transports the coil and travels on the travel path, the second photoelectric beam switch is located below the sleeve.

[0011] The coiled material is a steel coil or an aluminum coil.

[0012] The coil trolley is moved by a transmission device, and the transmission device is connected to the PLC.

[0013] The saddle is used for carrying or lifting the coil to the core shaft; the saddle is raised and lowered by a transmission motor through a hydraulic mechanism and is provided with a wire encoder for feedback.

[0014] A control method for an automatic coiling device is provided, using the automatic coiling device described above, wherein a first photoelectric beam switch is located above the coil at a fixed point at a height H1; a second photoelectric beam switch is located in area B of the coil carriage's travel path; a fixed difference between the coil carriage's saddle and the coil center is L0; and when the coil carriage reaches area D at the end of the travel path, the coil is inserted into the mandrel.

[0015] The method of controlling the coil trolley by PLC to automatically insert the coil onto the core shaft comprises the following steps:

[0016] Step A1, calculating the actual coil diameter of the coil, specifically: when the coil trolley is stationary in area A at the starting point of the coil trolley's travel path, with its saddle in the lowest position and a coil placed thereon, assuming the coordinates of the center point of the coil to be O1 (x1, y1), the winding device uses a wire encoder to record the top height of the coil trolley as 0, and the PLC controls the coil trolley saddle to lift the coil to the detection surface of the first photoelectric beamforming switch; at this time, the wire encoder records the top height of the coil trolley h1, and the PLC calculates the actual coil diameter D = H1 - h1 based on the on-off principle of the photoelectric beamforming switch, the relationship between the fixed height of the photoelectric beamforming switch sensor, and the height of the coil moving and rising;

[0017] Step A2: Calculate the initial coordinates of the center point of the coil in area A. Specifically, after the PLC detects the coil diameter, it controls the saddle to descend and reset. When the coil falls onto the saddle, the ordinate of the coil center point, y1 = D / 2 = (H1 - h1) / 2. At this point, the coordinates of the coil center point are O1 (x1, (H1 - h1) / 2).

[0018] Step A3: Calculate the height at which the coil is lifted by the coil trolley to a height at which the coil can be inserted into the mandrel. Specifically, the horizontal center of the mandrel is a fixed height, denoted as H2, and its coordinates are (0, H2). The height to which the coil is lifted by the coil trolley via the saddle is the difference between the mandrel's horizontal center height H2 and the vertical coordinate value of the coil center point in step A2 ((H1-h1) / 2), i.e., h3 = H2 - (H1-h1) / 2. h3 is used as the given value for the coil trolley to lift the coil. When the coil moves to a height at which the mandrel can be inserted in area A, the coordinates of the coil center point are O2 (x1, H2 - (H1-h1) / 2).

[0019] Step A4: Calculate the actual coil width. Specifically, when the coil trolley transports the coil to area B, the edge of the coil touches the second photoelectric switch, triggering it for the first time. The laser distance measuring device measures L1. When the edge of the coil leaves the second photoelectric switch, triggering it for the second time, the laser distance measuring device measures L2. The distance the coil trolley travels can be converted into the actual coil width, i.e., W1 = (L1 + L0) - (L2 + L0) = L1 - L2, where L0 is the fixed difference between the coil trolley saddle and the center of the coil.

[0020] Step A5: Calculate the coordinates of the center point of the coil. Specifically, while the coil width is being calculated in step A3, that is, when the second photoelectric beam switch in area B is triggered, the measured value recorded by the laser distance measuring device and half of the measured coil width are used to calculate the horizontal coordinate of the coil center point at this time: W2 = L2 + W1 / 2 = L2 + (L1 - L2) / 2 = (L1 + L2) / 2. The vertical coordinate is the fixed height of the core shaft. The coordinates of the center point at this time are O3 ((L1 + L2) / 2, H2 - (H1 - h1) / 2).

[0021] Step A6: Calculate the horizontal movement distance of the coil trolley. Specifically, in step A5, the horizontal coordinate value of the coil center point (L1 + L2) / 2 is used as the given value for the coil trolley to move horizontally to the D area to roll up the coil.

[0022] Step A7: The saddle lifts the coil to a height where it can be inserted into the core shaft. The coil trolley moves along the travel path toward area D on the core shaft, and the moving distance is the given value calculated in step A6, so that the coil is inserted into the core shaft.

[0023] The coil is hoisted by a crane to the saddle of the coil trolley in area A.

[0024] In step A7, the mandrel is inserted into the sleeve at the center of the coil.

[0025] The present invention can utilize a combination of devices such as a photoelectric beam switch and a laser rangefinder, combined with mathematical logic operations to control the height of the coil lifted by the trolley and the distance the coil is transported, and directly transport the coil to the center of the core shaft through the trolley; the coil loading method is upgraded from manual to automatic, thereby improving efficiency and reducing risks. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments:

[0027] Attachment Figure 1 This is a schematic diagram of the coil trolley at the starting point of its travel path;

[0028] Attachment Figure 2 is a schematic diagram of steps A1 to A5;

[0029] Attachment Figure 3 This is a schematic diagram of the coil trolley lifting the coil and moving it to the upper shaft at the core shaft;

[0030] In the figure: 1-first photoelectric beam switch; 2-second photoelectric beam switch; 3-coil; 4-sleeve; 5-mandrel; 6-laser distance measuring device; 7-coil trolley; 8-saddle. DETAILED DESCRIPTION

[0031] As shown in the figure, an automatic winding device is shown, which includes a coil trolley 7 and a PLC, and also includes a laser distance measuring device 6 located beside the core shaft; the coil trolley places the coil horizontally with a liftable saddle 8 and controls the vertical position of the coil; the travel path of the coil trolley, the core shaft, and the center axis of the coil are parallel to each other and are located in the same vertical working plane; a photoelectric beam switch group is provided on the travel path of the coil trolley; the PLC detects the specifications of the coil through the photoelectric beam switch group and the laser distance measuring device, measures the distance between the coil trolley and the core shaft through the laser distance measuring device, and controls the coil trolley to automatically insert the coil 3 into the core shaft 5.

[0032] The coiled material is a rolled body formed by winding a thin material on a sleeve 4; the length of the sleeve is not less than the width of the thin material; the length of the core shaft is not less than the length of the sleeve.

[0033] The photoelectric beam switch group includes a first photoelectric beam switch 1 provided at the starting point of the coil trolley's travel path, and also includes a second photoelectric beam switch 2 provided at the coil trolley's travel path; the detection directions of the first photoelectric beam switch and the second photoelectric beam switch are perpendicular to the travel path, the core shaft, and the working surface where the coil center axis is located;

[0034] When the saddle places the coil horizontally and the saddle is at the lowest point, the first photoelectric shooting switch is located above the coil;

[0035] When the coil trolley transports the coil and travels on the travel path, the second photoelectric beam switch is located below the sleeve.

[0036] The coiled material is a steel coil or an aluminum coil.

[0037] The coil trolley is moved by a transmission device, and the transmission device is connected to the PLC.

[0038] The saddle is used for carrying or lifting the coil to the core shaft; the saddle is raised and lowered by a transmission motor through a hydraulic mechanism and is provided with a wire encoder for feedback.

[0039] A control method for an automatic coiling device is provided, using the automatic coiling device described above, wherein a first photoelectric beam switch is located above the coil at a fixed point at a height H1; a second photoelectric beam switch is located in area B of the coil carriage's travel path; a fixed difference between the coil carriage's saddle and the coil center is L0; and when the coil carriage reaches area D at the end of the travel path, the coil is inserted into the mandrel.

[0040] The method of controlling the coil trolley by PLC to automatically insert the coil onto the core shaft comprises the following steps:

[0041] Step A1, calculating the actual coil diameter of the coil, specifically: when the coil trolley is stationary in area A at the starting point of the coil trolley's travel path, with its saddle in the lowest position and a coil placed thereon, assuming the coordinates of the center point of the coil to be O1 (x1, y1), the winding device uses a wire encoder to record the top height of the coil trolley as 0, and the PLC controls the coil trolley saddle to lift the coil to the detection surface of the first photoelectric beamforming switch; at this time, the wire encoder records the top height of the coil trolley h1, and the PLC calculates the actual coil diameter D = H1 - h1 based on the on-off principle of the photoelectric beamforming switch, the relationship between the fixed height of the photoelectric beamforming switch sensor, and the height of the coil moving and rising;

[0042] Step A2: Calculate the initial coordinates of the center point of the coil in area A. Specifically, after the PLC detects the coil diameter, it controls the saddle to descend and reset. When the coil falls onto the saddle, the ordinate of the coil center point, y1 = D / 2 = (H1 - h1) / 2. At this point, the coordinates of the coil center point are O1 (x1, (H1 - h1) / 2).

[0043] Step A3: Calculate the height at which the coil is lifted by the coil trolley to a height at which the coil can be inserted into the mandrel. Specifically, the horizontal center of the mandrel is a fixed height, denoted as H2, and its coordinates are (0, H2). The height to which the coil is lifted by the coil trolley via the saddle is the difference between the mandrel's horizontal center height H2 and the vertical coordinate value of the coil center point in step A2 ((H1-h1) / 2), i.e., h3 = H2 - (H1-h1) / 2. h3 is used as the given value for the coil trolley to lift the coil. When the coil moves to a height at which the mandrel can be inserted in area A, the coordinates of the coil center point are O2 (x1, H2 - (H1-h1) / 2).

[0044] Step A4: Calculate the actual coil width. Specifically, when the coil trolley transports the coil to area B, the edge of the coil touches the second photoelectric switch, triggering it for the first time. The laser distance measuring device measures L1. When the edge of the coil leaves the second photoelectric switch, triggering it for the second time, the laser distance measuring device measures L2. The distance the coil trolley travels can be converted into the actual coil width, i.e., W1 = (L1 + L0) - (L2 + L0) = L1 - L2, where L0 is the fixed difference between the coil trolley saddle and the center of the coil.

[0045] Step A5: Calculate the coordinates of the center point of the coil. Specifically, while the coil width is being calculated in step A3, that is, when the second photoelectric beam switch in area B is triggered, the measured value recorded by the laser distance measuring device and half of the measured coil width are used to calculate the horizontal coordinate of the coil center point at this time: W2 = L2 + W1 / 2 = L2 + (L1 - L2) / 2 = (L1 + L2) / 2. The vertical coordinate is the fixed height of the core shaft. The coordinates of the center point at this time are O3 ((L1 + L2) / 2, H2 - (H1 - h1) / 2).

[0046] Step A6: Calculate the horizontal movement distance of the coil trolley. Specifically, in step A5, the horizontal coordinate value of the coil center point (L1 + L2) / 2 is used as the given value for the coil trolley to move horizontally to the D area to roll up the coil.

[0047] Step A7: The saddle lifts the coil to a height where it can be inserted into the core shaft. The coil trolley moves along the travel path toward area D on the core shaft, and the moving distance is the given value calculated in step A6, so that the coil is inserted into the core shaft.

[0048] The coil is hoisted by a crane to the saddle of the coil trolley in area A.

[0049] In step A7, the mandrel is inserted into the sleeve at the center of the coil.

[0050] In this example, when the coil trolley transports the coil to area B, when the edge of the coil touches the second photoelectric switch, the switching value of the second photoelectric switch changes from 1 to 0; when the edge of the coil leaves the second photoelectric switch, the switching value of the second photoelectric switch changes from 0 to 1.

[0051] Example:

[0052] The process of this example is as follows:

[0053] (1) Coil preparation: Hoisted by a crane to the coil saddle on the trolley in area A.

[0054] (2) Actual roll diameter measurement: The roll trolley starts to lift the roll upward from the lowest position of the saddle in area A until it hits the photoelectric beam switch. The roll diameter is calculated based on the on-off principle of the photoelectric beam switch and the relationship between the fixed height of the sensor and the height of the upper roll trolley.

[0055] (3) Calculate the initial coordinates of the center point of the coil in area A: The coil trolley drops the coil to the saddle in area A. When it falls to the lowest point, the vertical coordinate value of the center point of the coil is converted by the coil diameter, and the value measured by the laser rangefinder is the horizontal coordinate value.

[0056] (4) Calculate the height of the coil trolley when it lifts the coil and rolls it up to the core shaft: Using the fixed height value of the core shaft, the difference between the vertical center height of the core shaft and the longitudinal coordinate of the center point of the coil is the height that the trolley needs to rise to the core shaft. This value is used as the given value for the coil trolley to lift the coil.

[0057] (5) Calculation of actual roll width: When the roll trolley transports the roll to area B, the photoelectric beam switch on-off principle is used to record the laser rangefinder measurement values ​​twice, and the difference between the two can be used as the measured roll width of the roll.

[0058] (6) Calculate the coordinates of the center point of the coil: When the roll width is calculated, that is, when the photoelectric switch in area B is turned on, the measured value recorded by the laser rangefinder and half of the measured roll width are the horizontal coordinates of the center point of the coil at this time, and the vertical coordinate is the fixed height value of the core shaft.

[0059] (7) Calculate the horizontal movement distance of the trolley: The horizontal coordinate value of the center point of the coil in step (6) is used as the given value for the coil trolley to move the coil horizontally to the D area.

Claims

1. An automatic winding device, characterized in that: The coil loading device includes a coil trolley and a PLC, as well as a laser distance measuring device located beside the mandrel. The coil trolley uses a liftable saddle to horizontally position the coil and control the vertical position of the coil. The coil trolley's travel path, the mandrel, and the coil's center axis are parallel to each other and located within the same vertical working plane. A photoelectric beam switch group is located within the coil trolley's travel path. The PLC uses the photoelectric beam switch group and the laser distance measuring device to detect coil specifications, measures the distance between the coil trolley and the mandrel using the laser distance measuring device, and controls the coil trolley to automatically insert the coil onto the mandrel. The coiled material is a roll-shaped body formed by winding a thin material on a sleeve; the length of the sleeve is not less than the width of the thin material; the length of the mandrel is not less than the length of the sleeve; The photoelectric beam switch group includes a first photoelectric beam switch provided at the starting point of the coil trolley's travel path, and also includes a second photoelectric beam switch provided at the coil trolley's travel path; The detection directions of the first photoelectric beam switch and the second photoelectric beam switch are perpendicular to the working surface where the travel path, the core shaft and the center axis of the coil are located; When the saddle places the coil horizontally and the saddle is at the lowest point, the first photoelectric shooting switch is located above the coil; When the coil trolley transports the coil on the travel path, the second photoelectric beam switch is located below the sleeve; The control method for the automatic coil loading device includes a first photoelectric beam switch located above the coil at a fixed point at a height of H1; a second photoelectric beam switch located in area B of the coil trolley's travel path; a fixed difference between the coil trolley's saddle and the coil center is L0; and when the coil trolley reaches area D at the end of the travel path, the coil is inserted into the mandrel. The method of controlling the coil trolley by PLC to automatically insert the coil onto the core shaft comprises the following steps: Step A1, calculating the actual coil diameter of the coil, specifically: when the coil trolley is stationary in area A at the starting point of the coil trolley's travel path, with its saddle in the lowest position and a coil placed thereon, assuming the coordinates of the center point of the coil to be O1 (x1, y1), the winding device uses a wire encoder to record the top height of the coil trolley as 0, and the PLC controls the coil trolley saddle to lift the coil to the detection surface of the first photoelectric beamforming switch; at this time, the wire encoder records the top height of the coil trolley h1, and the PLC calculates the actual coil diameter D = H1 - h1 based on the on-off principle of the photoelectric beamforming switch, the relationship between the fixed height of the photoelectric beamforming switch sensor, and the height of the coil moving and rising; Step A2: Calculate the initial coordinates of the center point of the coil in area A. Specifically, after the PLC detects the coil diameter, it controls the saddle to descend and reset. When the coil falls onto the saddle, the ordinate of the coil center point, y1 = D / 2 = (H1 - h1) / 2. At this point, the coordinates of the coil center point are O1 (x1, (H1-h1) / 2). Step A3: Calculate the height at which the coil is lifted by the coil trolley to a height at which the coil can be inserted into the mandrel. Specifically, the horizontal center of the mandrel is a fixed height, denoted as H2, and its coordinates are (0, H2). The height to which the coil is lifted by the coil trolley via the saddle is the difference between the mandrel's horizontal center height H2 and the vertical coordinate value of the coil center point in step A2 ((H1-h1) / 2), i.e., h3 = H2 - (H1-h1) / 2. h3 is used as the given value for the coil trolley to lift the coil. When the coil moves to a height at which the mandrel can be inserted in area A, the coordinates of the coil center point are O2 (x1, H2 - (H1-h1) / 2). Step A4: Calculate the actual coil width. Specifically, when the coil trolley transports the coil to area B, the edge of the coil touches the second photoelectric switch, triggering it for the first time. The laser distance measuring device measures L1. When the edge of the coil leaves the second photoelectric switch, triggering it for the second time, the laser distance measuring device measures L2. The distance the coil trolley travels can be converted into the actual coil width, i.e., W1 = (L1 + L0) - (L2 + L0) = L1 - L2, where L0 is the fixed difference between the coil trolley saddle and the center of the coil. Step A5: Calculate the coordinates of the center point of the coil. Specifically, while the coil width is being calculated in step A3, that is, when the second photoelectric beam switch in area B is triggered, the measured value recorded by the laser distance measuring device and half of the measured coil width are used to calculate the horizontal coordinate of the coil center point at this time: W2 = L2 + W1 / 2 = L2 + (L1 - L2) / 2 = (L1 + L2) / 2. The vertical coordinate is the fixed height of the core shaft. The coordinates of the center point at this time are O3 ((L1 + L2) / 2, H2 - (H1 - h1) / 2). Step A6: Calculate the horizontal movement distance of the coil trolley. Specifically, in step A5, the horizontal coordinate value of the coil center point (L1 + L2) / 2 is used as the given value for the coil trolley to move horizontally to the D area to roll up the coil. Step A7: The saddle lifts the coil to a height where it can be inserted into the core shaft. The coil trolley moves along the travel path toward area D on the core shaft, and the moving distance is the given value calculated in step A6, so that the coil is inserted into the core shaft.

2. The automatic winding device according to claim 1, characterized in that: The coiled material is a steel coil or an aluminum coil.

3. The automatic winding device according to claim 1, characterized in that: The coil trolley is moved by a transmission device, and the transmission device is connected to the PLC.

4. The automatic winding device according to claim 1, characterized in that: The saddle is used for carrying or lifting the coil to the core shaft; the saddle is raised and lowered by a transmission motor through a hydraulic mechanism and is provided with a wire encoder for feedback.

5. The automatic winding device according to claim 1, characterized in that: The coil is hoisted by a crane to the saddle of the coil trolley in area A.

6. The automatic winding device according to claim 1, characterized in that: In step A7, the mandrel is inserted into the sleeve at the center of the coil.

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