A software control method and system for an automatic composite material feeding device

Abstract

The application provides a kind of composite material automatic feeding device software control method and system, comprising: executing initialization program;Carrying out program error check, judge whether there is program error, in the presence of program error, initialization program is executed in a loop, in the absence of program error, running main program;Running manual program, automatic program and debugging program;Executing manual function, automatic function and debugging function;Executing automatic function and continuous transmission feeding.The application solves the technical problems of low operation precision and low production efficiency caused by relying on manual operation.

Description

Technical Field

[0001] This invention relates to the field of composite material processing control, and specifically to a software control method and system for an automatic composite material feeding device. Background Technology

[0002] QY board decorative composite material is favored and widely used by foreign decorators due to its excellent characteristics such as light weight, high impact resistance, low thermal conductivity, corrosion resistance, and easy cleaning. Its adoption rate in China is also increasing. The number of companies manufacturing and producing this material has also increased.

[0003] Currently, the level of electrical automation in the domestic production of this composite material is relatively low. The production process is as follows: First, the upper layer of the composite material is cut from rolls to the required width using a separate cutting device. The cut material is then manually collected and transported to both sides of the lower layer material conveying equipment. Next, a production worker on each side of the conveying equipment visually lays the upper layer material onto the lower layer material in an overlapping manner. Finally, the multi-layer material with the upper layer material laid on it passes through a high-temperature baking zone and an extrusion molding zone to process the required two or more layers of material into a multi-layer composite material.

[0004] Several problems exist in this production process. First, the required upper-layer material needs to be cut by a separate cutting machine. After cutting, a production worker is needed to transport the material to the designated location, and then the material is manually placed. Laying the material requires two workers simultaneously, one on each side of the continuous conveyor line. Second, because of the continuous production, it is difficult to control the overlap length and skew angle of the upper-layer material within the allowable error range when placing the material manually in a short period of time, which easily leads to inconsistent product quality.

[0005] The prior art patent document CN1829595A, entitled "Apparatus and Method for Forming Composite Reinforcing Members and Strengthening Components," describes an elongated composite structural member that exhibits a desired cross-sectional geometry when transverse to its length. An apparatus may include a base on which a basic elongated core is mounted. One or more roller configurations, at least partially complementary to the core, are used to roll and apply pressure on one or more layers of composite material on the core. The core may be disposed on a turntable and configured to exhibit a curved, elongated geometry to form an elongated member that is at least partially curved or arcuate. From the specific implementation of this prior art, it is clear that it employs control rollers and preheating devices in the operation of multi-layer composite material pressing and the operation of heating specific material areas. However, from the specific embodiments of this prior art, it is evident that it is only applicable to multi-layer fibrous materials pre-impregnated with thermosetting resin, and the prior art solution is only applicable to specific configurations such as curved or arcuate elongated members, thus limiting the applicability of the prior art.

[0006] The existing invention application document CN104552538A, entitled "Manufacturing Method of Green, Environmentally Friendly, High-Strength, and Anti-Deformation Solid Wood Composite Door," includes the following steps: softening and miniaturizing logs to produce thin boards; separating the thin boards into a face panel and a core material, and drying them; splicing them into a whole board, separating the face panel and core material, selecting whole boards with transverse grain from the core material as balancing tension boards, arranging them into multi-layer boards, and applying glue; pressing them together with a hot press to produce multi-layer boards, curing them, trimming the four sides, and sanding them to a fixed thickness; cutting the multi-layer boards into strips of a fixed width to make anti-deformation core material, and fixing the thickness; using medium-density fiberboard and anti-deformation core material to make a structural board, curing it, trimming the four sides, sanding it to a fixed thickness, carving, milling, milling lines, and finishing to produce a high-strength, anti-deformation solid wood composite door panel. This existing technology relies heavily on existing equipment and manual operation in the splicing, multi-layer pressing, cutting, and forming operations of composite boards, resulting in low production efficiency and low precision in splicing, cutting, and forming operations.

[0007] In summary, existing technologies suffer from low operational precision and low production efficiency due to reliance on manual labor. Summary of the Invention

[0008] The technical problem to be solved by this invention is how to solve the problem of low operational accuracy and low production efficiency caused by reliance on manual labor.

[0009] The present invention solves the above-mentioned technical problems by adopting the following technical solution: A software control method for an automatic composite material feeding device includes:

[0010] S1. Execute the initialization procedure;

[0011] S2. Perform program error checking to determine if there are any program errors. If a program error occurs, execute the initialization program repeatedly. If no program error occurs, run the main program. Step S2 includes:

[0012] S21. The single-layer composite material is continuously pulled out of the hopper and conveyed forward by the auxiliary traction. The single-layer composite material is conveyed to the corresponding length by the feeding drive, and the feeding is stopped for the cutter to cut.

[0013] S22. The single-layer composite material is cut using a cutter. The cut single-layer composite material is then picked up by the cylinder under the transverse feeding electric cylinder and transported to the preset cut material position by the transverse feeding electric cylinder. The material is then released by the cylinder under the transverse feeding electric cylinder, causing the transverse feeding electric cylinder to return to the ready transverse feeding position. The longitudinal feeding electric cylinder moves to the preset cut material position, picks up the single-layer composite material transported by the transverse feeding electric cylinder, and transports it forward to the bottom layer composite material that is continuously running below by the longitudinal feeding electric cylinder. The material is then released by the cylinder under the longitudinal feeding electric cylinder.

[0014] S23. While the longitudinal feeding electric cylinder is conveying the single-layer composite material, a second piece of the single-layer composite material is delivered using a feeding servo and transmitted to the transverse feeding electric cylinder for transverse conveying.

[0015] S24. Multiple pieces of the single-layer composite material are sequentially fed by a transverse feeding electric cylinder and a longitudinal feeding electric cylinder, with the overlapping portion accounting for 5%-10% of the width of a single piece of single-layer composite material, continuously and uniformly covering the bottom composite material to form the material to be baked.

[0016] S25. The materials to be baked are combined through a heating and baking process to obtain a multilayer composite material;

[0017] S3. Run manual programs, automatic programs, and debug programs;

[0018] S4. Perform manual, automatic, and debugging functions;

[0019] S5. Execute the automatic function and continuously transmit and feed materials.

[0020] This invention develops a corresponding software control system and integrates it with corresponding transmission equipment, cutting equipment, feeding equipment, and underlying material conveying equipment into a complete system, realizing the integration of multiple small standalone devices into a single system. This reduces human error, lowers the workload of production staff, and reduces the amount of manual operation required.

[0021] In a more specific technical solution, the feeding servo in step S23 is a multi-axis drive system, which includes: a V / F control unit, a vector control unit, and a servo control unit. The V / F control unit, the vector control unit, and the servo control unit are interconnected through a high-speed drive interface DRIVE-CLiQ.

[0022] The various modules of this invention (including the control unit, rectification / feedback module, motor module, sensor module, and motor encoder, etc.) are interconnected via a high-speed drive interface DRIVE-CLiQ, thereby achieving high-speed command transmission and real-time accuracy of information feedback. This allows for precise control of the length of each piece of material delivered, achieving millimeter-level accuracy with zero error.

[0023] In a more specific technical solution, in step S2, a preset touch screen is used to display preset dynamic points and their operating parameters. Dynamic display screens corresponding to the preset dynamic points are collected and added according to actual demand parameters, so as to provide real-time feedback on the position of the single-layer composite material and the bottom composite material.

[0024] The screen used in the actual operation of this invention is relatively simple. The corresponding dynamic points have been reserved in the program. When it is put into actual use, the corresponding dynamic screen will be added according to the actual needs to provide real-time feedback on the position of the sheet metal, which is convenient for viewing and maintenance operations.

[0025] In a more specific technical solution, step S3 includes: selecting the manual / automatic control mode using a preset centralized control display device and setting the system hardware parameters. The manual / automatic control mode includes: manual cutter operation and automatic stop. The system hardware parameter setting operation also includes:

[0026] S31, Enable feed servo and adjust cutter;

[0027] S32. Set a leveling cylinder to adjust the position of the single-layer composite material after being conveyed by the transverse feeding cylinder to ensure that the material is neat and even. Set the conveying length of the transverse feeding cylinder and the longitudinal feeding cylinder respectively.

[0028] S33. Set the conveying speed of the main conveyor for the underlying composite material.

[0029] In a more specific technical solution, in step S33, the running linear speed of the continuous conveying roller of the composite material bottom layer is set as a reference data for the overall running speed rhythm in the software control method of the automatic composite material feeding device.

[0030] In a more specific technical solution, step S33 also includes:

[0031] S331. Measure the transmission linear velocity of the underlying composite material using a preset encoder to obtain the operating linear velocity. Step S331 further includes:

[0032] S3311. Using preset logic, the time for laying a single piece of the bottom layer composite material is obtained by processing the bottom layer composite material to run the single piece of the top layer composite material.

[0033] S3312. The upper layer laying operation time for continuously laying single pieces of composite material is obtained by using preset logic calculation.

[0034] S3313. Obtain a preset fixed speed value, and process the bottom layer laying time and the upper layer laying operation time accordingly to obtain the running linear speed.

[0035] S332. When the difference between the running linear speed and the set speed exceeds the preset range, a speed difference warning is generated and issued. Step S332 further includes:

[0036] S3321. During the laying of the upper composite material, there is an overlap between two consecutive upper composite materials. Set a range of ratios of the overlap to the width of a single upper composite material.

[0037] S3322. Set the inverter speed of the bottom composite material and obtain the speed measured by the encoder. Use the speed measured by the encoder as the reference speed and process the speed difference between the reference speed and the inverter speed to obtain the alarm signal.

[0038] In a more specific technical solution, step S32 further includes: during the synchronous operation of the feeding servo and the transverse feeding electric cylinder, when the two driving actions are inconsistent, the tearing action on the fed material is used to generate an electric cylinder speed correction signal to match the driving actions.

[0039] In a more specific technical solution, step S32 also includes a zero-finding and reset operation of the electric cylinder, thereby adjusting the operating accuracy of the electric cylinder.

[0040] The zeroing function for the feeding cylinder at the bottom of the display screen of this invention addresses the issue that after long-term operation or after the entire equipment has been moved, the position of the feeding cylinder may not be accurate enough for a single delivery, or the zero point of the cylinder may be lost. After the zeroing operation, the cylinder will move back to the calibrated zero position, thus restoring the delivery position to an accurate state.

[0041] In a more specific technical solution, step S32 further includes: setting a suction time so that the suction disk waits for a preset time and performs a suction operation at an appropriate time.

[0042] After the material is sucked up, the telescopic mechanism rebounds, and the suction plate leaves the discharge plane. After the rebound is in place, a short period of time is waited to avoid excessive shaking of the suction plate. This waiting period allows the suction plate to return to a stable state, ensuring the efficiency and accuracy of the material sucking operation.

[0043] In a more specific technical solution, a software control system for an automatic composite material feeding device includes:

[0044] The initialization module is used to execute the initialization program;

[0045] The main program execution module performs program error checking to determine if any errors exist. If an error occurs, it repeatedly executes the initialization program; otherwise, it runs the main program. The main program execution module is connected to the initialization module. The main program execution module includes:

[0046] A single-layer composite material conveying unit is used to continuously pull and convey single-layer composite materials from the hopper with auxiliary traction and forward. The single-layer composite material is conveyed to the corresponding length by the feeding drive and the feeding is stopped for cutting by the cutter.

[0047] The cutting unit uses a cutter to cut the single-layer composite material. The cylinder under the transverse feeding electric cylinder picks up the cut single-layer composite material and transports it to the preset cut material position through the transverse feeding electric cylinder. Then the cylinder under the transverse feeding electric cylinder releases the material, so that the transverse feeding electric cylinder returns to the transverse feeding position. The cutting unit is connected to the single-layer composite material conveying unit.

[0048] The feeding servo is used to feed out the second single-layer composite material and transmit it to the transverse feeding electric cylinder for transverse conveying. The feeding servo is connected to the cutting unit.

[0049] The covering unit is used to move the longitudinal feeding electric cylinder to the preset position of the cut material, adsorb the single-layer composite material conveyed by the transverse feeding electric cylinder, and convey it forward to the bottom layer composite material that is continuously running below through the longitudinal feeding electric cylinder. Then, the cylinder under the longitudinal feeding electric cylinder releases the material, so that multiple pieces of the single-layer composite material are sequentially fed by the transverse feeding electric cylinder and the longitudinal feeding electric cylinder, with the overlapping part accounting for 5%-10% of the width of the single-layer composite material, continuously and evenly covering the bottom layer composite material to form the material to be baked. The covering unit is connected to the feeding servo.

[0050] The baking and synthesis unit is used to combine the materials to be baked through a heating and baking process to obtain a multilayer composite material. The baking and synthesis unit is connected to the covering unit.

[0051] The program execution and debugging module is used to run manual programs, automatic programs, and debug programs;

[0052] The execution module is used to perform manual, automatic, and debugging functions. The execution module is connected to the program execution and debugging module.

[0053] The continuous feeding module is used to perform automatic functions and continuously transmit and feed materials. The continuous feeding module is connected to the execution module.

[0054] Compared with existing technologies, this invention has the following advantages: This invention integrates a corresponding software control system with corresponding transmission equipment, cutting equipment, feeding equipment, and underlying material conveying equipment into a single system, realizing the integration of multiple small standalone devices into a single system. This reduces human error, lowers the workload of production staff, and reduces the amount of manual operation required.

[0055] The various modules of this invention (including the control unit, rectification / feedback module, motor module, sensor module, and motor encoder, etc.) are interconnected via a high-speed drive interface DRIVE-CLiQ, thereby achieving high-speed command transmission and real-time accuracy of information feedback. This allows for precise control of the length of each piece of material delivered, achieving millimeter-level accuracy with zero error.

[0056] The screen used in the actual operation of this invention is relatively simple. The corresponding dynamic points have been reserved in the program. When it is put into actual use, the corresponding dynamic screen will be added according to the actual needs to provide real-time feedback on the position of the sheet metal, which is convenient for viewing and maintenance operations.

[0057] The zeroing function for the feeding cylinder at the bottom of the display screen of this invention addresses the issue that after long-term operation or after the entire equipment has been moved, the position of the feeding cylinder may not be accurate enough for a single delivery, or the zero point of the cylinder may be lost. After the zeroing operation, the cylinder will move back to the calibrated zero position, thus restoring the delivery position to an accurate state.

[0058] After the initial material suction is completed, the telescopic mechanism rebounds, and the suction disc moves away from the discharge plane. After rebounding to its final position, a short waiting period is allowed to prevent excessive vibration of the suction disc and to allow it to stabilize, thus ensuring efficient and accurate material suction. This invention solves the technical problems of low operational accuracy and low production efficiency caused by reliance on manual labor in existing technologies. Attached Figure Description

[0059] Figure 1 This is a schematic diagram of the hardware configuration of the software control system for an automatic composite material feeding device according to Embodiment 1 of the present invention;

[0060] Figure 2 This is a schematic diagram of data flow processing for a software control method of an automatic composite material feeding device according to Embodiment 2 of the present invention;

[0061] Figure 3 This is a schematic diagram of the software control method steps for an automatic composite material feeding device according to Embodiment 2 of the present invention;

[0062] Figure 4 This is a schematic diagram of the centralized control interface of Embodiment 3 of the present invention;

[0063] Figure 5 This is a schematic diagram of the electric cylinder parameter setting interface in Embodiment 3 of the present invention. Detailed Implementation

[0064] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0065] Example 1

[0066] Hardware configuration:

[0067] like Figure 1 As shown, in this embodiment, the software control system requires particularly high precision in drive operation, so Siemens' S120 servo motor is used as the feeding drive. The S120 is a multi-axis drive system integrating V / F control, vector control, and servo control, featuring a modular design. The various modules (including control units, rectifier / feedback modules, motor modules, sensor modules, and motor encoders) are interconnected via the high-speed drive interface DRIVE-CLiQ to achieve high-speed command transmission and real-time accuracy of information feedback. This allows for precise control of the length of each piece of material fed out, achieving millimeter-level accuracy with zero error.

[0068] In this embodiment, the widely used Siemens PLC module is employed, while the CPU uses the high-performance 315-2DP module. Current communication networks are undergoing rapid upgrades, with most communications trending towards Ethernet. However, when connecting to third-party drivers, DP communication technology is very mature, while Ethernet communication technologies such as Profinet are less mature. Therefore, a CPU using PROFIBUS communication is selected in this instance. However, if conditions permit in the future, a driver supporting Ethernet and a CPU with an Ethernet interface will be used.

[0069] The system configuration diagram shows a human-machine interface (HMI) using a large TP1200 Siemens touchscreen to display equipment operation information and issue transmission commands. The main controller is a Siemens 315-2DP controller, used to process various computational information and logic control instructions. The auxiliary traction drive uses a Siemens MM440 frequency converter to continuously transport the rolled material forward. The feeding traction uses a Siemens S120 servo drive to precisely control the length of each sheet of material being transported. After a sheet is transported, it is cut by a cutter before another sheet is transported. The transverse feeding device uses a Festo CMMP-AS M3 electric cylinder. Festo cylinders are superior to most other electric cylinders in terms of position control and speed response. This cylinder has low error in linear motion and low cumulative error over long strokes, resulting in good controllability. The longitudinal feeding device also uses a Festo CMMP-AS M3 electric cylinder.

[0070] The human-machine interface, controller, and four drives described above achieve the following functions: First, the auxiliary traction continuously pulls and conveys the single-layer composite material from the hopper forward. After the feeding drive conveys the material to the corresponding length, it stops and waits for the cutter to cut it. After the cutter cuts the material, the cylinder under the transverse feeding electric cylinder conveys the material to a designated position, puts it down, and returns to a specific position to wait for the transverse feeding of the next piece of material. At this time, the feeding servo sends out the second piece of material to the transverse feeding electric cylinder for forward conveying. At the same time, the longitudinal feeding electric cylinder conveys the material delivered by the transverse feeding electric cylinder forward onto the continuously running bottom layer of composite material, thus evenly and continuously covering the single-layer composite material on the continuously running material below, and then passing through the next heating and baking synthesis process.

[0071] Example 2

[0072] Since the most important aspect of the control system is the accuracy of the position, the transmission position must be accurate, the overall conveying rhythm must be accurate, and it must be able to achieve uniform, continuous, and straight laying of a single piece of material on the underlying material in order to complete the continuous transmission of the material.

[0073] like Figure 2 and Figure 3 As shown, the software control method for an automatic composite material feeding device provided by the present invention includes the following steps:

[0074] S1. Execute the initialization procedure;

[0075] S2. Perform a program error check to determine if there are any program errors;

[0076] S3. If an error occurs, re-execute the initialization program; if no error occurs, run the main program.

[0077] In this embodiment, both the transverse feeding electric cylinder and the feeding servo include a precision speed measuring device. In this embodiment, let the running length of a single feeding by the feeding servo be L1, and the running length of the feeding electric cylinder be L2. Using L2 as the calculation base distance, the running distance difference of the drive device is (L1-L2).

[0078] In this embodiment, assuming that tearing occurs when the feeding servo is 5mm slower than the feeding electric cylinder, then when L1-L2 < -5mm, the feeding servo is accelerated; when L1 < -10mm, a larger acceleration is applied; and when L1 < -2mm, the additional acceleration is stopped. The same process is applied when the distance difference between the two running feeds is positive.

[0079] In this embodiment, the time required for the bottom layer of composite material to run through the upper layer of single-piece composite material is: T = L / V

[0080] In the formula, T is the time required for the bottom layer to operate to the width of the single piece of material to be laid in the upper layer, L is the width of the single piece of composite material to be laid in the upper layer, and V represents the linear speed of the bottom composite material.

[0081] In this embodiment, the upper composite material needs to be continuously laid on with single-piece composite materials within this time. The time used is T. Then T = T1 + T2 + T3 + L1 / V1 + T4 + T5 + T6 + T7 + (L2 + L3) / V2 + T8 + T9.

[0082] In the formula, T is the time required for the bottom layer to operate and the upper layer to lay a single piece of material; T1 is the time for the cylinder under the horizontal feeding electric cylinder to suck up material at the initial position; T2 is the time for the cylinder under the horizontal feeding electric cylinder to rise after sucking up material; T3 is the time for the horizontal feeding electric cylinder to wait for the cutter to cut the material; T4 is the time for the cylinder under the horizontal feeding electric cylinder to release material; T5 is the action time of the leveling cylinder; T6 is the time for the cylinder under the longitudinal feeding electric cylinder to suck up material; T7 is the time for the cylinder under the longitudinal feeding electric cylinder to rise after sucking up material; T8 is the time for the cylinder under the longitudinal feeding electric cylinder to release material; T9 is the predicted loss time; L1 is the width of the bottom composite material (i.e., the length of the upper composite material); L2 is the width of the upper composite material; L3 is the fixed length of the operating platform minus the width of the upper material; V1 is the operating speed of the horizontal feeding electric cylinder; and V2 is the operating speed of the longitudinal feeding electric cylinder.

[0083] From the two formulas above, we can see that time T is the same and is obtained through calculation. Time T1~T9 are known, and L1~L3 are known. V1 and V2 are unknown. A fixed value for V2 is given in advance, and then the value of V1 is calculated.

[0084] In this embodiment, when laying the upper layer material, two consecutive pieces of material overlap. It is assumed that the overlap of a single piece of material is designed to be 10% of its width, with a minimum allowable overlap width of 5%. The bottom composite material uses a frequency converter-driven device and also has a pre-set speed encoder. If the set frequency converter speed is V1 and the encoder-measured speed is V2, then V2 is used as the base speed for calculation. The difference between the two speeds is ((V1-V2) / V2). 100%; when the speed difference is greater than 5%, an alarm will be triggered, allowing production personnel to check the specific situation on-site and take appropriate action.

[0085] S4. Run manual programs, automatic programs, and debug programs;

[0086] S5. Perform manual, automatic, and debugging functions;

[0087] S6. Execute automatic function and continuously feed material;

[0088] S7. The program execution ends when the feeding ends.

[0089] Example 3

[0090] Example of a scene:

[0091] like Figure 4 As shown, the actual software system is in the late stage of testing, and all functional operations have been basically implemented. The screen used in the test is relatively simple. The corresponding dynamic points have been reserved in the program. When it is put into actual use later, corresponding dynamic screens will be added according to actual needs to provide real-time feedback on the position of the sheet metal for easy viewing.

[0092] The centralized control screen is used to select manual / automatic control mode, enable servo motors, adjust cutters and leveling cylinders, and set parameters such as the length of material transported by the horizontal and vertical feeding cylinders, and the conveying speed of the lower material conveyor. A detailed description follows:

[0093] On the left side of the screen, we see the host speed and the actual traction speed. Here, speed refers to the linear speed of the continuous conveyor rollers of the composite material's bottom layer. All operating speeds in the system are based on the speed of the bottom layer material. This is because the cut sheets are evenly and continuously laid on top of the bottom layer material, and then subsequently heated and pressurized to form a multi-layer composite material. The set host speed commands the bottom layer material to operate continuously at this speed, controlling the feeding rhythm. The actual traction speed refers to the actual conveyor linear speed of the bottom layer material measured by an encoder. If the speed differs significantly from the set speed, a warning is issued, allowing production personnel to determine if a speed difference exists and take appropriate action. The transverse material length setting refers to the length of a single sheet that needs to be fed. Each sheet is cut to this length, and then accurately delivered to the corresponding position using the longitudinal material centerline as a reference. The transverse material width setting refers to the distance a single sheet needs to be fed by the longitudinal feeding cylinder. Length and width corrections are used in continuous production where machine stoppage is not possible, but the actual material delivery deviates. In such cases, an actual transport distance correction is given; this value can be positive or negative. The feed cylinder revision value refers to the synchronous operation of the feed servo and the transverse feed electric cylinder. If the two drive actions are inconsistent, the fed material will be torn. At this time, the speed of the electric cylinder is corrected to match the two actions completely. The unit here is percentage.

[0094] On the right side of the screen, "Manual Initialization" and "Automatic Initialization" refer to providing an initial state for the S120 servo and electric cylinder in two different operating modes, preparing them for the next action. "Manual Start" and "Automatic Start" refer to starting the system in manual and automatic modes, respectively. Manual start involves manual jogging, executing each step one by one. In automatic mode, the entire system continuously transports single-piece materials, evenly laying them on top of the underlying material. "Manual Cutter" is used in conjunction with manual mode; when feeding material for the first time, the front end may not be even. Manually aligning the material before starting automatic mode is necessary. "Automatic Stop" refers to stopping the equipment and returning it to its initial state in automatic mode if it malfunctions but does not pose a safety hazard. "Mode Selection" refers to choosing between automatic and manual mode. "Cutter Adjustment Button" allows repeated adjustments to the cutter after a single action, using the button to drive the cutter and observe whether it returns to the correct position after stopping. "Manual Alignment Cylinder" refers to whether a single action of the alignment cylinder evens out the laterally fed material, awaiting transport by the longitudinal feeding electric cylinder.

[0095] like Figure 5As shown, the electric cylinder parameter setting screen is used to set various parameters related to the electric cylinder. The zeroing functions for the feeding and conveying cylinders at the bottom of the screen refer to situations where, after long-term operation or after the entire equipment has been moved, the position of a single conveying operation may not be precise. This could be due to the loss of the cylinder's zero point. After zeroing, the cylinder will return to the calibrated zero position, thus restoring accurate conveying position. The suction time refers to the time required during the feeding process. The negative pressure cylinder attached to the electric cylinder is used to pick up the material, then the electric cylinder conveys it forward, releasing the pressure at the corresponding position to lower the material. However, different single-layer materials may require different suction times. If the time is too short, the material will not be picked up; if the time is too long, it will affect the overall cycle time. Therefore, it is necessary to manually observe the specific suction time required to set an appropriate time. After the material suction is completed, the telescopic mechanism will rebound, causing the suction plate to leave the feeding plane. After the rebound is complete, you need to wait for a while, otherwise the suction plate may shake a lot. Wait a short time to allow the suction plate to return to a stable state before continuing to feed materials.

[0096] In this embodiment, the present invention calls a block of Festo electric cylinder to work normally through a preset program, enabling a single electric cylinder to work according to the corresponding instructions. The variable cylinder_logic_data1.cylinder1_rata is used to give the speed of the electric cylinder. The value assigned to this variable is different when the electric cylinder runs to different positions, and the operating speed is also different.

[0097] The variable "cylinder_logic_data1".cylinder1_site is used to determine the specific position to which the electric cylinder should operate. In actual operation, the electric cylinder needs to stop at three positions: the initial position, the cutting position, and the material discharge position at the end of the transmission. By transmitting the corresponding position value to this variable and combining it with the speed variable above to give a reasonable speed, the electric cylinder can be made to stop at the corresponding position and execute the corresponding command.

[0098] In this embodiment, the servo logic judgment instructions and servo feeding have the following problems: First, manual feeding is required initially to allow the cutter to remove the uneven material at the very tip. Then, in automatic mode, the first position is to send the material to a location where the horizontal feeding cylinder can pick it up. After the horizontal feeding cylinder picks up the material, it synchronously sends the material to the cutting position of the cutter. After the cutter cuts the material, it returns to the first automatic feeding state. The following code snippet, `A %L0.0; AN"servo_use_data".judge_position_pulse1;= %L0.2;A %L0.2; JNB Label_8; L "servo_use_data".distance2; T "servo_use_data".site_of_servo;Label_8:NOP 0; A %L0.2; JNBLabel_9; L 16#047f; T "servo_use_data".servo_control_word;`, is used to express that when an electric cylinder picks up material, the servo can synchronously transfer the material with the electric cylinder.

[0099] In this embodiment, the most difficult part of the software system is position calculation. There are multiple drivers, and the accuracy of each position is at the millimeter level or even smaller. Only when the position is accurate can the system have the original design meaning. If the position is inaccurate or even worse than manual laying, then the feeding system loses its original meaning.

[0100] Using conventional frequency converters and encoders makes it difficult to achieve such high precision. While a simple servo motor can accurately measure the length of the conveyed material, ensuring the material is transported straight is crucial. Ordinary servos can only guarantee high accuracy in the distance their output shaft travels, but they cannot determine whether the material is straight and without tilting. This is where an electric cylinder conveying device comes in. For longer distances, the electric cylinder fixes the conveying mechanism to the lower part of a straight linear transmission mechanism, ensuring a straight path for the material. This guarantees that the material is always delivered in a straight line without deviation. Using a conventional frequency converter for auxiliary traction, a servo motor for main traction, and an electric cylinder for feeding effectively solves this problem.

[0101] During the operation of the mechanical mechanism, the electric cylinder needs to remain in multiple positions: initial position, zeroing position, cutting action position, and material discharge position at the end of the transmission process. However, conflicts exist among these positions. How can we ensure that the calibration of these positions does not become chaotic? How can we distinguish between two different positions when they use the same coordinate point? For example, both the zeroing position and the initial position may need to be marked at a physical zero point; how can we differentiate between them? Furthermore, how do we determine when the equipment has reached a designated position to decide whether to execute the next instruction? The equipment has a certain inertia; when a stop command is issued, the equipment may have exceeded the intended stopping position, making it unable to execute the next instruction, and the entire system will be stuck. Here, a preset program is used to determine the position, and other programs are used to handle situations where the program stops.

[0102] Through the aforementioned procedure, the initial position and zero-finding actions are reasonably distinguished when passing the physical zero point. When performing zero-finding, no position calibration is performed; detecting the physical zero point signifies completion of the zero-finding action, and the device returns to the zero point position. When setting the initial position, the previous position is recorded. When passing a value close to zero, a signal is triggered to indicate that this is a return to the initial position rather than a zero-finding action. After passing the zero point, the device is re-marked and returns to the designated initial position. When the equipment has inertial errors, two methods are used to eliminate jamming. First, extensive testing is conducted to determine the distance the equipment has traveled too far or too little, thus setting a reasonable advance to reduce errors. Simultaneously, multiple tests are conducted to determine the error range, and a certain error allowance is given. When the equipment stops within the target position plus the allowable error range, it is considered to have reached the designated position. Finally, if the equipment remains stationary for an extended period after reaching a certain position, an alarm is triggered, requiring manual intervention.

[0103] In summary, this invention develops a corresponding software control system and integrates it with corresponding transmission equipment, cutting equipment, feeding equipment, and underlying material conveying equipment into a complete system, realizing the integration of multiple small standalone devices into a single system. This reduces human error, lowers the workload of production staff, and reduces the amount of manual operation required.

[0104] The various modules of this invention (including the control unit, rectification / feedback module, motor module, sensor module, and motor encoder, etc.) are interconnected via a high-speed drive interface DRIVE-CLiQ, thereby achieving high-speed command transmission and real-time accuracy of information feedback. This allows for precise control of the length of each piece of material delivered, achieving millimeter-level accuracy with zero error.

[0105] The screen used in the actual operation of this invention is relatively simple. The corresponding dynamic points have been reserved in the program. When it is put into actual use, the corresponding dynamic screen will be added according to the actual needs to provide real-time feedback on the position of the sheet metal, which is convenient for viewing and maintenance operations.

[0106] The zeroing function for the feeding cylinder at the bottom of the display screen of this invention addresses the issue that after long-term operation or after the entire equipment has been moved, the position of the feeding cylinder may not be accurate enough for a single delivery, or the zero point of the cylinder may be lost. After the zeroing operation, the cylinder will move back to the calibrated zero position, thus restoring the delivery position to an accurate state.

[0107] After the initial material suction is completed, the telescopic mechanism rebounds, and the suction disc moves away from the discharge plane. After rebounding to its final position, a short waiting period is allowed to prevent excessive vibration of the suction disc and to allow it to stabilize, thus ensuring efficient and accurate material suction. This invention solves the technical problems of low operational accuracy and low production efficiency caused by reliance on manual labor in existing technologies.

[0108] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A software control method for an automatic composite material feeding device, characterized by, The method comprises: S1, executing an initialization program; S2, performing a program error check to determine whether there is a program error, and if there is a program error, repeatedly executing the initialization program, and if there is no program error, running a main program, wherein the S2 comprises: S21, continuously drawing and conveying single-layer composite materials out of the material bin forward by auxiliary traction, conveying the single-layer composite materials out of the corresponding length by using the feeding drive, and stopping the conveying for cutting by the cutter; S22, cutting the single-layer composite materials by the cutter, absorbing the cut single-layer composite materials by the cylinder under the transverse feeding cylinder, conveying the single-layer composite materials to the preset cut material position by the transverse feeding cylinder, and releasing the materials by the cylinder under the transverse feeding cylinder to make the transverse feeding cylinder return to the standby transverse feeding position; moving the longitudinal feeding cylinder to the preset cut material position, absorbing the single-layer composite materials conveyed by the transverse feeding cylinder, conveying the single-layer composite materials forward to the continuously running bottom-layer composite materials by the longitudinal feeding cylinder, and releasing the materials by the cylinder under the longitudinal feeding cylinder; S23, while the longitudinal feeding cylinder is conveying the single-layer composite materials, feeding the second single-layer composite materials by the feeding servo and conveying the second single-layer composite materials to the transverse feeding cylinder for transverse conveying; S24, making a plurality of the single-layer composite materials sequentially pass through the transverse feeding cylinder and the longitudinal feeding cylinder, and continuously and uniformly covering the bottom-layer composite materials with a lap joint portion accounting for 5%-10% of the width of a single single-layer composite material to form a material to be baked; S25, baking the material to be baked together by the heating and baking synthesis process to obtain a multi-layer composite material; S3, running a manual program, an automatic program, and a debugging program; S4, executing a manual function, an automatic function, and a debugging function; S5, executing the automatic function and continuously conveying the materials.

2. The software control method of the composite material automatic feeding device according to claim 1, characterized in that, The feeding servo in the S23 is a multi-axis driving system, which comprises a V / F control unit, a vector control unit, and a servo control unit, and the V / F control unit, the vector control unit, and the servo control unit are connected to each other through a high-speed driving interface DRIVE-CLiQ.

3. The software control method of the composite material automatic feeding device according to claim 2, characterized in that, In the S2, preset dynamic points and their operation parameters are displayed by using a preset touch screen, dynamic display screens corresponding to the preset dynamic points are added according to actual demand parameters, and the positions of the single-layer composite materials and the bottom-layer composite materials are fed back in real time.

4. The software control method of the composite material automatic feeding device according to claim 1, characterized in that, The S3 comprises selecting a manual and automatic control mode and setting system hardware parameters by using a preset centralized control display device, wherein the manual and automatic control mode comprises manual and automatic parking of the cutter, and the operation of the system hardware parameter setting further comprises: S31, enabling the feeding servo and adjusting the cutter; S32, setting a correction cylinder to adjust the position of the single-layer composite materials conveyed by the transverse feeding cylinder to ensure that the materials are regular and flat, and setting the conveying material length of the transverse feeding cylinder and the longitudinal feeding cylinder, respectively; S33, setting the conveying speed of the transmission host of the bottom-layer composite materials.

5. The software control method of the composite material automatic feeding device according to claim 4, characterized in that, The S33 further comprises:

6. The software control method of the composite material automatic feeding device according to claim 5, characterized in that, The S33 further comprises: S331, measuring the transmission line speed of the bottom layer composite material by using a preset encoder to obtain the running line speed, wherein the S331 further comprises: S3311, processing the bottom layer laying single piece time of the single piece composite material laid by the bottom layer composite material by using a preset logic; S3312, calculating the upper layer laying operation time of the single piece composite material completed by the upper layer composite material; S3313, obtaining a preset fixed speed value, and processing the bottom layer laying single piece time and the upper layer laying operation time to obtain the running line speed; S332, generating and issuing a speed difference warning when the speed difference between the running line speed and the set speed exceeds a preset interval, wherein the S332 further comprises: S3321, setting the ratio interval of the overlap portion of the upper layer composite material to the width of the single piece of the upper layer composite material during the laying process of the upper layer composite material; S3322, setting the frequency converter speed of the bottom layer composite material and obtaining the encoder measured speed, taking the encoder measured speed as the reference speed, and processing the alarm signal by using the speed difference between the reference speed and the frequency converter speed.

7. The software control method of the composite material automatic feeding device according to claim 4, characterized in that, The S32 further comprises: when the two driving actions are inconsistent during the synchronous operation of the feeding servo and the transverse feeding cylinder, an electric cylinder speed correction signal is generated by the tearing and pulling action on the material, so as to match the consistency of the driving actions.

8. The software control method of the composite material automatic feeding device according to claim 4, characterized in that, The S32 further comprises an electric cylinder zero search reset operation, so as to adjust the running accuracy of the electric cylinder.

9. The software control method of the composite material automatic feeding device according to claim 4, characterized in that, The S32 further comprises: setting the suction time, so that the suction disc waits for a preset time and performs the suction operation at the applicable time.

10. A software control system for an automatic composite material loading device, characterized in that, The system comprises: An initialization module is configured to execute an initialization program; A main program running module is configured to perform program error checking, determine whether there is a program error, and, when a program error occurs, execute the initialization program in a loop, and, when the program error does not occur, run a main program. The main program running module is connected with the initialization module, and the main program running module comprises: A single layer composite material conveying unit is configured to continuously convey the single layer composite material out of the warehouse and forward by auxiliary traction, convey the single layer composite material out of a corresponding length by feeding drive, and stop conveying for cutting by a cutter; A cutting unit is configured to cut the single layer composite material by the cutter, adsorb the cut single layer composite material by a cylinder under a transverse feeding cylinder, convey the cut single layer composite material to a preset cut material position by the transverse feeding cylinder, release the material by the cylinder under the transverse feeding cylinder, and return the transverse feeding cylinder to a transverse feeding position. The cutting unit is connected with the single layer composite material conveying unit. A feeding servo is used to send out the second piece of the single-layer composite material and transmit it to the horizontal feeding cylinder for horizontal transmission. The feeding servo is connected with the cutting unit. A covering unit is used to move the longitudinal feeding cylinder to the preset position of the cut material, adsorb the single-layer composite material transported by the horizontal feeding cylinder, transport it to the continuously running bottom-layer composite material by the longitudinal feeding cylinder, release the material by the cylinder under the longitudinal feeding cylinder, and make the multiple pieces of the single-layer composite material sequentially pass through the horizontal feeding cylinder and the longitudinal feeding cylinder, so that the overlapped part accounts for 5%-10% of the width of the single-layer composite material, continuously and uniformly cover the bottom-layer composite material, and form the material to be baked. The covering unit is connected with the feeding servo. A baking synthesis unit is used to pass the material to be baked through a heating baking synthesis process to obtain the multi-layer composite material. The baking synthesis unit is connected with the covering unit. A program running debugging module is used to run a manual program, an automatic program and a debugging program. An execution module is used to execute a manual function, an automatic function and a debugging function. The execution module is connected with the program running debugging module. A continuous feeding module is used to execute the automatic function and continuously transmit the feeding. The continuous feeding module is connected with the execution module.

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