Automatic control system and method applicable to door frame production

Abstract

The present invention discloses an automatic control system and method applicable to the production of door frames. The automatic control system includes an uncoiling control module, a first buffer control module, a flat punching control module, a second buffer control module, a forming control module, a process hole detection module, a forming stamping control module, a retracting control module, a host computer, a first conveying control module, and a second conveying control module. The present invention realizes the automatic control of door frame generating equipment, thereby saving a large amount of labor costs, improving the production efficiency and the consistency of the produced frame parts, and being applicable to the manufacture of a large number of frame parts. In addition, the method based on process hole positioning introduced in the system accurately realizes the punching of flat punching holes and the stamping of imprinting holes, thereby improving the production accuracy of the door frame generating equipment.

Description

Technical Field

[0001] The present invention belongs to the technical field of door frame production, and in particular relates to an automatic control system and method suitable for door frame production. Background Art

[0002] Traditional door frame production typically involves manual processing. First, a 1mm to 2.2mm thick, 290mm wide steel sheet is installed on a decoiler. The decoiler then unwinds the steel material. The coiled steel is then passed through a forming machine for final shaping, resulting in the desired door frame workpiece (frame element). The finished steel pieces are then cut to length and manually transported to various punching stations for punching different types of frame elements. These punched holes include hook holes, mounting holes, exposed hinge holes, and latch holes. Finally, the cut pieces are re-set to length and then withdrawn, completing the production of the various frame elements. The resulting frame elements are then assembled to form the door frame, which is then shipped. This door frame processing method requires a large number of employees to transport materials between various stations, which is time-consuming and labor-intensive, and requires a high level of manual labor. Consequently, this method produces poor product consistency, low production efficiency, and high production costs, making it suitable only for small-batch production. Furthermore, this processing method lacks real-time monitoring of the production process, making it impossible to provide fault warnings.

[0003] Therefore, a plan for building an automated production line for door frames is urgently needed to replace the traditional door frame processing line that uses manual participation. Summary of the Invention

[0004] In view of this, an object of the present invention is to provide an automatic control system and method suitable for door frame production in order to overcome one or more deficiencies mentioned in the background technology.

[0005] The object of the present invention is achieved through the following technical solutions:

[0006] First aspect

[0007] A first aspect of the present invention proposes an automatic control system suitable for door frame generation, which is applied to door frame production equipment. The door frame production equipment includes an unwinding module, a flat punching module, a frame forming module, a retreat module, and a forming and stamping module provided with an imprinting mold. Each imprinting mold has a corresponding imprinting hole. A first encoder, a flat punching mold, and a process hole mold are provided in the flat punching module. The process hole mold is provided between the unwinding module and the flat punching mold. The first encoder moves following the material segment arriving at the flat punching module. A second encoder and a first photoelectric switch are provided in the frame forming module. The second encoder moves following the material segment arriving at the frame forming module. The first encoder and the second encoder are used to record position values. The automatic control system includes:

[0008] The uncoiling control module, connected to the uncoiling module, is used to control the material discharging action of the uncoiling module;

[0009] The flat punching control module, connected to the flat punching module, is used to control the process hole die to open process holes on the material section reaching the process hole die, and then obtain the first reading and the production material list, and determine the first position value according to the first reading and the production material list. The first position value is the reading of the first encoder corresponding to moving the material section reaching the process hole die to each flat punching corresponding flat punching die, so that the material section can be shifted according to each determined first position value, and then the flat punching die corresponding to the first position value performs the punching action of the corresponding flat punching on the material section. The first reading is the reading of the first encoder when the material section discharged by the uncoiling module is moved to the process hole die;

[0010] The forming control module, connected to the frame forming module, is used to control the process of the forming action, and the forming action is the action performed by the frame forming module on the material section after flat punching;

[0011] The process hole detection module, connected to the first photoelectric switch and the second encoder, is used to obtain the second reading and the first induction signal generated after the first photoelectric switch is triggered. The second reading is the reading of the second encoder when the first photoelectric switch generates the first induction signal. Among them, when the process hole reaches the position of the first photoelectric switch, the first photoelectric switch is triggered to generate the first induction signal;

[0012] The forming stamping control module, connected to the forming stamping module, is used to obtain the second reading and the production material list, and then determine the second position value according to the second reading and the production material list. The second position value is the reading of the second encoder when moving the formed material section to each imprinting hole corresponding imprinting die, so that the formed material section can be shifted according to each determined second position value, and the imprinting die corresponding to the second position value performs the imprinting action of the corresponding imprinting hole on the formed material section;

[0013] The retreat control module, connected to the retreat module, is used to control the retreat module to perform a shearing action, and the shearing action is to cut off the waste material and process holes in the imprinted material section;

[0014] Among them, the production material list includes the distance values between each pre-opened flat punching hole and the process hole of the material section, and the distance values between each pre-opened imprinting hole and the process hole of the material section.

[0015] Preferably, a first servo motor is further provided in the flat punching module. The first servo motor is connected to a third encoder for recording the rotational displacement value of the first servo motor. The first servo motor is used to drive the movement of the material section reaching the flat punching module. A second servo motor is further provided in the frame forming module. The second servo motor is connected to a fourth encoder for recording the rotational displacement value of the second servo motor. The second servo motor is used to drive the movement of the material section reaching the frame forming module. The automatic control system further includes:

[0016] A first conveying control module, connected to the first encoder and the first servo motor, is used to determine whether the readings of the first encoder and the third encoder are within a first preset range at the same moment. If not, an abnormal conveying alarm is given.

[0017] A second conveying control module, connected to the second encoder and the second servo motor, is used to determine whether the readings of the second encoder and the fourth encoder are within a second preset range at the same moment. If not, an abnormal conveying alarm is given.

[0018] Preferably, a first buffer zone is further provided between the uncoiling module and the flat punching module, and a second buffer zone is further provided between the flat punching module and the frame forming module. The automatic control system further includes:

[0019] A first buffer control module, connected to the first buffer zone, is used to stop the pulling and conveying of the material section by the flat punching module when receiving the second induction signal sent by the first buffer zone, and to stop the feeding of the uncoiling module when receiving the third induction signal sent by the first buffer zone. Among them, the second induction signal is generated when the material section touches the upper limit position of the first buffer zone, and the third induction signal is generated when the material section touches the lower limit position of the first buffer zone.

[0020] A second buffer control module, connected to the second buffer zone, is used to stop the pulling and conveying of the material section by the frame forming module when receiving the fourth induction signal sent by the second buffer zone, and to stop the output of the material section by the flat punching module when receiving the fifth induction signal sent by the second buffer zone. Among them, the fourth induction signal is generated when the material section touches the upper limit position of the second buffer zone, and the fifth induction signal is generated when the material section touches the lower limit position of the second buffer zone.

[0021] Preferably, a second photoelectric switch is further provided in the frame forming module. The second photoelectric switch is arranged between the first photoelectric switch and the flat punching module.

[0022] The process hole detection module is also connected to a second optoelectronic switch, and is configured to obtain a sixth induction signal generated after the second optoelectronic switch is triggered. After obtaining the sixth induction signal, it decelerates the transmission section between the frame forming module and the forming stamping module. Wherein, when the process hole reaches the position of the second optoelectronic switch, the second optoelectronic switch is triggered to generate the sixth induction signal.

[0023] Preferably, the automatic control system further includes a host computer, and the host computer is respectively connected to the uncoiling control module, the flat punching control module, the forming control module, the process hole detection module, the forming stamping control module, and the retracting control module.

[0024] Preferably, the production bill of materials further includes the length data of the material section; the process hole detection module is further configured to determine whether the absolute value of the difference between two adjacent second readings obtained and the difference between the length data of the material section are within a third preset range. If not, an alarm for abnormal material section length is given.

[0025] Preferably, the uncoiling control module is further configured to obtain the remaining material characteristic parameters of the uncoiling module, and determine whether there is material in the uncoiling module according to the remaining material characteristic parameters. If not, a no-material alarm is given.

[0026] The beneficial effects of the first aspect of the present invention are as follows:

[0027] (1) Through the settings of the uncoiling control module, the flat punching control module, the frame forming control module, the process hole detection module, the forming stamping control module, and the retracting control module, the automatic control of the door frame generating device is realized, thus saving a large amount of labor costs, improving the production efficiency and the consistency of the produced frame parts, and being applicable to the manufacture of a large number of frame parts;

[0028] (2) When the flat punching module performs the punching operation on each flat punching, the process hole die is the first punching position where the material section first arrives, and is used to open the process hole. Then, by using the process hole as the origin position for punching positioning, combined with the processing parameters corresponding to the material section in the production bill of materials (the distance values between each flat punching pre-processed on the material section and the process hole), the distance value that the first servo motor needs to drive the material section to travel to obtain each flat punching by counterpunching is determined. This control process introduces the process hole and uses the process hole as the origin positioning method to achieve accurate punching of the flat punching, thereby improving the production accuracy of the door frame generating device;

[0029] (3) When the forming stamping module performs the stamping actions of each stamping hole, the process hole detection module combines with the first photoelectric switch to detect the process hole. After sensing the process hole, it determines the real-time position of the process hole through the second reading obtained, and combines with the processing parameters corresponding to the material section in the production bill of materials (the distance values between the pre-processed stamping holes and the process hole in the material section) to determine the distance value that the second servo motor needs to drive the material section to travel in order to stamp each stamping hole. This control process adopts the method of process hole positioning, realizes the precise punching of stamping holes, and thus improves the production accuracy of the door frame generating device;

[0030] (4) When detecting the process hole, further combining with the second photoelectric switch improves the positioning accuracy of the process hole;

[0031] (5) Through the settings of the first conveying control module and the second conveying control module, the closed-loop control of the first encoder and the first servo motor and the closed-loop control of the second encoder and the second servo motor are realized. When a conveying abnormality alarm occurs, abnormal situations such as material jamming are detected in a timely manner, and the gear ratio correction of the first servo motor and the second servo motor is carried out in a timely manner, realizing the online fault monitoring of the production process;

[0032] (6) Through the settings of the first buffer control module and the second buffer control module, the online monitoring of the first buffer material area and the second buffer material area is realized, and abnormal situations such as excessive material or insufficient material are detected in a timely manner, thereby ensuring the production efficiency;

[0033] (7) By the judgment of the process hole detection module on whether the length of the material section is normal, the length abnormality of the material section is detected in a timely manner.

[0034] Second aspect

[0035] The second aspect of the present invention proposes an automatic control method applicable to the production of door frames, which is applied to a door frame production device. The door frame production device includes an uncoiling module, a flat punching module, a frame forming module, a retracting module, and a forming stamping module provided with a stamping die. Each stamping die is provided with each stamping hole. The flat punching module is provided with a first encoder, a flat punching die, and a process hole die. The process hole die is arranged between the uncoiling module and the flat punching die. The first encoder moves along with the material section reaching the flat punching module. The frame forming module is provided with a second encoder and a first photoelectric switch. The second encoder moves along with the material section reaching the frame forming module. The first encoder and the second encoder are used to record position values; the automatic control method includes:

[0036] Controlling the feeding action of the uncoiling module, and obtaining the remaining material characteristic parameters of the uncoiling module, and judging whether there is material in the uncoiling module according to the remaining material characteristic parameters. If not, a no-material alarm is given;

[0037] The control process hole die opens process holes for the material section arriving at the process hole die, then obtains a first reading and a production bill of materials, and determines a first position value according to the first reading and the production bill of materials. The first position value is the reading of the first encoder corresponding to moving the material section arriving at the process hole die to each flat punching hole corresponding to the flat punching die, so that the material section can be shifted according to each determined first position value. Then, the flat punching die corresponding to the first position value performs the punching action of the corresponding flat punching hole on the material section. The first reading is the reading of the first encoder when the material section released by the uncoiling module is moved to the process hole die;

[0038] Perform process control on the forming action, where the forming action is the action performed by the frame forming module on the material section after flat punching;

[0039] Obtain a first induction signal generated after the first photoelectric switch is triggered and a second reading. The second reading is the reading of the second encoder when the first photoelectric switch generates the first induction signal. Among them, when the process hole reaches the position of the first photoelectric switch, the first photoelectric switch is triggered to generate the first induction signal;

[0040] Obtain the second reading and the production bill of materials, and then determine a second position value according to the second reading and the production bill of materials. The second position value is the reading of the second encoder when moving the formed material section to each embossing hole corresponding embossing die, so that the formed material section can be shifted according to each determined second position value. The embossing die corresponding to the second position value performs the embossing action of the corresponding embossing hole on the formed material section;

[0041] Control the retracting module to perform a shearing action, where the shearing action is to cut off the waste material and process holes in the embossed material section;

[0042] Among them, the production bill of materials includes the distance values between each pre-opened flat punching hole and the process hole of the material section, and the distance values between each pre-opened embossing hole and the process hole of the material section.

[0043] Preferably, a first servo motor is further provided in the flat punching module. The first servo motor is connected with a third encoder for recording the rotational displacement value of the first servo motor. The first servo motor is used to drive the material section arriving at the flat punching module to move. A second servo motor is further provided in the frame forming module. The second servo motor is connected with a fourth encoder for recording the rotational displacement value of the second servo motor. The second servo motor is used to drive the material section arriving at the frame forming module to move; A first buffer material area is further provided between the uncoiling module and the flat punching module, and a second buffer material area is further provided between the flat punching module and the frame forming module;

[0044] The automatic control method further includes:

[0045] Judge whether the readings of the first encoder and the third encoder at the same moment are within the first preset range. If not, an alarm for abnormal conveying is given.

[0046] Judge whether the readings of the second encoder and the fourth encoder at the same moment are within the second preset range. If not, an alarm for abnormal conveying is given.

[0047] When the second induction signal sent by the first buffer area is obtained, stop the pulling and conveying of the material section by the flat punching module, and when the third induction signal sent by the first buffer area is obtained, stop the feeding of the uncoiling module, where the second induction signal is generated when the material section touches the upper limit position of the first buffer area, and the third induction signal is generated when the material section touches the lower limit position of the first buffer area.

[0048] When the fourth induction signal sent by the second buffer area is obtained, stop the pulling and conveying of the material section by the frame forming module, and when the fifth induction signal sent by the second buffer area is obtained, stop the output of the material section by the flat punching module, where the fourth induction signal is generated when the material section touches the upper limit position of the second buffer area, and the fifth induction signal is generated when the material section touches the lower limit position of the second buffer area.

[0049] Preferably, a second photoelectric switch is further arranged in the frame forming module, and the second photoelectric switch is arranged between the first photoelectric switch and the flat punching module; the production bill of materials further includes the length data of the material section.

[0050] The automatic control method further includes:

[0051] Obtain the sixth induction signal generated after the second photoelectric switch is triggered. After obtaining the sixth induction signal, decelerate the transmission section between the frame forming module and the forming stamping module, where when the process hole reaches the position of the second photoelectric switch, the second photoelectric switch is triggered to generate the sixth induction signal.

[0052] Judge whether the difference between the absolute value of the difference between two adjacent second readings obtained and the length data of the material section is within the third preset range. If not, an alarm for abnormal length of the material section is given.

[0053] The second aspect of the present invention brings the same beneficial effects as the first aspect, which will not be elaborated here. Description of the Drawings

[0054] Figure 1 It is a schematic connection diagram between an automatic control system applicable to the production of door frames and a door frame production device;

[0055] Figure 2 It is a schematic diagram of a device including the automatic control system implemented in Embodiment 1;

[0056] Figure 3 The first part of the schematic diagram of the production line for processing a material section into a door frame member by a door frame production device;

[0057] Figure 4 The second part of the schematic diagram of the production line for processing a material section into a door frame member by a door frame production device. Specific embodiments

[0058] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative efforts fall within the scope of protection of the present invention.

[0059] Embodiment 1

[0060] Refer to Figures 1-4, this embodiment provides an automatic control system applicable to the production of door frames, which is applied to door frame production equipment. The door frame production equipment is used to process a material section into a frame part under the control of the automatic control system. The material section is usually a steel sheet. The door frame production equipment includes an uncoiling module, a flat punching module, a frame forming module, a retracting module, and a forming stamping module provided with an embossing die. Among them, the uncoiling module usually includes an uncoiler for uncoiling and a variable-frequency motor connected to the uncoiler and used for feeding. A first buffer material area for caching materials is arranged between the uncoiling module and the flat punching module. The first buffer material area is provided with an elevated rack. The flat punching module pulls and conveys the material section through the elevated rack. The first buffer material area is provided with a microswitch near the variable-frequency motor for sensing when the material section reaches the upper limit position, and a current loop is arranged on the ground of the first buffer material area for sensing when the material section reaches the lower limit position; a second buffer material area with the same internal structure as the first buffer material area is arranged between the flat punching module and the frame forming module. The flat punching module is usually a hydraulic punching device for flat plate punching. A first encoder for recording position values, a flat punching die, and a process hole die are arranged in the hydraulic punching device. The first encoder moves following the material section reaching the flat punching module. The process hole die is arranged between the uncoiling module and the flat punching die, that is, the material section first reaches the process hole die during production, also known as the No. 1 punching position, and the process hole is opened by the process hole die, and various types of flat punching are opened by each flat punching die. The frame forming module is usually a forming device. A second encoder for recording position values and a first photoelectric switch are arranged in the forming device. The second encoder moves following the material section reaching the frame forming module. Preferably, the first photoelectric switch is a groove-type photoelectric switch. The forming stamping module is usually an embossing device for post-forming punching and embossing. The embossing device includes an embossing die, and each embossing die opens each embossing hole in a one-to-one correspondence. The retracting module usually includes a chasing and shearing device, and the chasing and shearing device includes a shearing device (such as scissors) and a hydraulic device for moving the shearing device, etc. In this embodiment, the forming device, the embossing device, and the chasing and shearing device are welded into one body. In addition, temperature sensors, upper in-place sensors, and lower in-place sensors, etc. are also arranged in the flat punching module, the forming stamping module, and the retracting module. Among them, the temperature sensor measures the hydraulic oil temperature, and the upper in-place sensor and the lower in-place sensor sense whether the punching is in place.

[0061] Specifically, the automatic control system includes: an uncoiling control module, a first buffer control module, a flat punching control module, a second buffer control module, a forming control module, a process hole detection module, a forming stamping control module, a retracting control module, and a host computer.

[0062] The uncoiling control module, connected to the uncoiling module, is used to control the material discharging action of the uncoiling module. In addition, further, the uncoiling control module also obtains the remaining material characteristic parameters of the uncoiling module, and judges whether there is material in the uncoiling module according to the remaining material characteristic parameters. If not, a no-material alarm is given. The process of generating the remaining material characteristic parameters by the uncoiling module adopts the process in the general embodiment. For example, a reflective sensor is set in the uncoiling module, and the generated signal of the reflective sensor is the remaining material characteristic parameter. When the reflective sensor does not sense the material section output by the uncoiler, the generated signal of the reflective sensor has a level inversion, and it can be judged that there is no material in the uncoiler according to this level inversion, and then a no-material alarm is given. When the reflective sensor continuously senses the material section output by the uncoiler, the generated signal of the reflective sensor does not have a level inversion, and it can be judged that there is material in the uncoiler.

[0063] The first buffer control module, connected to the first buffer area, is used to stop the pulling and conveying of the material section by the flat punching module when obtaining the second induction signal sent by the first buffer area, and stop the material discharging of the uncoiling module when obtaining the third induction signal sent by the first buffer area. Among them, the second induction signal is generated when the material section touches the upper limit position of the first buffer area, and the third induction signal is generated when the material section touches the lower limit position of the first buffer area. Specifically:

[0064] After the material section in the first buffer area touches the upper limit position, the microswitch set at the upper limit position is pressed by the material section to generate the second induction signal; after the material section in the first buffer area touches the lower limit position, the current loop set at the lower limit position is connected by the material section to generate the third induction signal.

[0065] The flat punching control module, connected to the flat punching module, is used to control the process hole die to open process holes in the material section reaching the process hole die, and then obtain the first reading and the production bill of materials, and determine the first position value according to the first reading and the production bill of materials. The first position value is the reading of the first encoder corresponding to moving the material section reaching the process hole die to the flat punching die corresponding to each flat punching, so that the material section can be shifted according to each determined first position value, and then the flat punching die corresponding to the first position value performs the punching action of the corresponding flat punching on the material section. The first reading is the real-time reading of the first encoder when the material section released by the uncoiling module is moved to the process hole die. Among them, the production bill of materials includes the distance values between each flat punching pre-opened in the material section and the process hole, which is also called the station position of each flat punching with the process hole as the origin 0 position. Generally, when producing frame parts, multiple frame parts are produced, involving multiple material sections. The production bill of materials distinguishes the processing tasks of each material section through the processing serial number, that is, each material section corresponds to a processing serial number, and sequential processing is carried out according to the processing serial number. Each material section is made into its corresponding frame part. When calculating the first position value, in this embodiment, the first position values of the current processing serial number and the 9 processing serial numbers after this processing serial number are calculated. The following content takes the position relationship between the flat punching die and the process hole die described in Table 1, the processing parameters for processing the material section with the processing serial number 1 into the corresponding frame part in Table 2, and the processing parameters for processing the material section with the processing serial number 2 into the corresponding frame part in Table 3 as examples to illustrate the calculation process of the first position value. The contents of Table 1, Table 2, and Table 3 have been imported into the production bill of materials:

[0066] Table 1

[0067]

[0068] Table 2

[0069]

[0070] Table 3

[0071]

[0072] Assume that the first reading of the first encoder is 100, and flat punching is performed on the material section with the processing serial number 1:

[0073] Step 1, open the first hole (hole number 3): The first position value = 100 + 60 + 440. Therefore, when the reading of the first encoder reaches 600, the flat punching die performs the punching of hole number 3, and the distance that the material section needs to travel is 500;

[0074] Process step 2, opening the second hole (hole number 4): The first position value = 100 + 228 + 760. Therefore, when the reading of the first encoder reaches 1088, the flat punching die is used to open the hole numbered 4. Then the distance that the material section needs to travel is 988;

[0075] And so on;

[0076] For the material section with the processing serial number 2, perform flat punching opening:

[0077] Process step 1, opening the first hole (hole number 3): The first position value = 1163 + 100 + 60 + 440. Therefore, when the reading of the first encoder reaches 1763, the flat punching die is used to open the hole numbered 3. Then the distance that the material section needs to travel is 1663;

[0078] Process step 2, opening the second hole (hole number 4): The first position value = 1163 + 100 + 228 + 760. Therefore, when the reading of the first encoder reaches 2251, the flat punching die is used to open the hole numbered 4. Then the distance that the material section needs to travel is 2151;

[0079] Similarly, the first position values of the material sections with processing serial numbers 3 - 10 can be obtained. Then when the material section moves according to the first position value, by comparing all the first position values of the processing serial numbers 1 - 10 calculated, and then moving according to the smallest first position value. When the material section reaches the flat punching die corresponding to the flat punching at this first position value, perform the corresponding punching action. When the accumulated value after the first reading of the first encoder is greater than the length data of the material section with the processing serial number 1, it indicates that the flat punching processing of the material section with the processing serial number 1 is completed.

[0080] The second buffer control module, connected to the second buffer material area, is used to stop the pulling and conveying of the material section by the frame forming module when obtaining the fourth induction signal sent by the second buffer material area, and to stop the output of the material section by the flat punching module when obtaining the fifth induction signal sent by the second buffer material area. Among them, the fourth induction signal is generated when the material section touches the upper limit position of the second buffer material area, and the fifth induction signal is generated when the material section touches the lower limit position of the second buffer material area. Specifically:

[0081] When the material section in the second buffer material area touches the upper limit position, the micro switch set at the upper limit position is pressed by the material section to generate the fourth induction signal; when the material section in the second buffer material area touches the lower limit position, the current loop set at the lower limit position is connected by the material section to generate the fifth induction signal.

[0082] The forming control module, connected to the frame forming module, is used to perform process control on the forming action, and the forming action is the action performed by the frame forming module on the material section after flat punching.

[0083] The process hole detection module is connected to the first optoelectronic switch and the second encoder, and is used to obtain the second reading and the first induction signal generated after the first optoelectronic switch is triggered. The second reading is the real-time reading of the second encoder when the first optoelectronic switch generates the first induction signal. Among them, when the process hole reaches the position of the first optoelectronic switch, due to the light transmission of the process hole, the first optoelectronic switch is triggered to generate the first induction signal.

[0084] Optionally, a second optoelectronic switch is further arranged in the frame forming module. The second optoelectronic switch is preferably a groove-type optoelectronic switch, and the second optoelectronic switch is arranged between the first optoelectronic switch and the flat punching module. The process hole detection module is also connected to the second optoelectronic switch and is used to obtain the sixth induction signal generated after the second optoelectronic switch is triggered. After obtaining the sixth induction signal, the transmission section between the frame forming module and the forming stamping module is decelerated. Among them, when the process hole reaches the position of the second optoelectronic switch, due to the light transmission of the process hole, the second optoelectronic switch is triggered to generate the sixth induction signal.

[0085] Optionally, the process hole detection module is further used to judge whether the difference between the absolute value of the difference between two adjacent second readings obtained and the length data of the material section is within a third preset range. If not, an alarm for abnormal material section length is given.

[0086] The forming stamping control module is connected to the forming stamping module and is used to obtain the second reading and the production material list, and then determine the second position value according to the second reading and the production material list. The second position value is the reading of the second encoder corresponding to moving the formed material section to the corresponding stamping die for each embossing hole, so that the formed material section can be shifted according to each determined second position value, and the corresponding stamping die corresponding to the second position value performs the embossing action on the formed material section for the corresponding embossing hole. Among them, the production material list includes the distance values between each pre-opened embossing hole and the process hole of the material section, which is also called the station position of each embossing hole with the process hole as the origin 0 position. The calculation principle of the second position value is the same as that of the first position value, and the process principle of shifting and embossing the formed material section according to the second position value is the same as the process principle of shifting and punching the material section reaching the process hole die according to the first position value, which will not be elaborated here, and those skilled in the art can directly deduce it.

[0087] The retreat control module is connected to the retreat module and is used to control the retreat module to perform a shearing action, and the shearing action is to cut off the waste material and the process hole in the embossed material section.

[0088] The host computer is connected to the uncoiling control module, the first buffer control module, the flat punching control module, the second buffer control module, the forming control module, the process hole detection module, the forming stamping control module, and the retracting control module, and is used to execute the input, saving, modification, etc. of the production bill of materials.

[0089] As a further implementation process, a first servo motor is also provided in the flat punching module. The first servo motor is connected to a third encoder for recording the rotational displacement value of the first servo motor. The first servo motor is used to drive the material section reaching the flat punching module to move. A second servo motor is also provided in the frame forming module. The second servo motor is connected to a fourth encoder for recording the rotational displacement value of the second servo motor. The second servo motor is used to drive the material section reaching the frame forming module to move; the automatic control system further includes a first conveying control module and a second conveying control module, and the host computer is also connected to the first conveying control module and the second conveying control module.

[0090] The first conveying control module is connected to the first encoder and the first servo motor, and is used to judge whether the readings of the first encoder and the third encoder are within a first preset range at the same moment. If not, an abnormal conveying alarm is given.

[0091] The second conveying control module is connected to the second encoder and the second servo motor, and is used to judge whether the readings of the second encoder and the fourth encoder are within a second preset range at the same moment. If not, an abnormal conveying alarm is given.

[0092] Embodiment 2

[0093] This embodiment provides an automatic control method applicable to the production of door frames, which is applied to the door frame production equipment in Embodiment 1. The automatic control method includes:

[0094] Controlling the feeding action of the uncoiling module, and obtaining the remaining material characteristic parameters of the uncoiling module, and judging whether there is material in the uncoiling module according to the remaining material characteristic parameters. If not, a no-material alarm is given;

[0095] Controlling the process hole die to open a process hole for the material section reaching the process hole die, and then obtaining the first reading and the production bill of materials, and determining the first position value according to the first reading and the production bill of materials. The first position value is the reading of the first encoder when the material section reaching the process hole die is moved to each flat punching corresponding to the flat punching die, so that the material section is shifted according to each determined first position value, and then the flat punching die corresponding to the first position value performs the punching action of the corresponding flat punching on the material section. The first reading is the reading of the first encoder when the material section released by the uncoiling module is moved to the process hole die;

[0096] Perform process control on the forming action, where the forming action is the action performed by the frame forming module on the material section after flat punching;

[0097] Obtain the first induction signal and the second reading generated after the first optoelectronic switch is triggered. The second reading is the reading of the second encoder when the first optoelectronic switch generates the first induction signal. Among them, when the process hole reaches the position of the first optoelectronic switch, the first optoelectronic switch is triggered to generate the first induction signal;

[0098] Obtain the second reading and the production bill of materials, and then determine the second position value according to the second reading and the production bill of materials. The second position value is the reading of the second encoder corresponding to moving the formed material section to the corresponding stamping die for each stamping hole, so that the formed material section can be shifted according to each determined second position value, and the stamping die corresponding to the second position value performs the stamping action of the corresponding stamping hole on the formed material section;

[0099] Control the retraction module to perform a shearing action, where the shearing action is to cut off the waste material and the process hole in the stamped material section;

[0100] Among them, the production bill of materials includes the distance values between each pre-opened flat punching hole and the process hole of the material section, and the distance values between each pre-opened stamping hole and the process hole of the material section.

[0101] Furthermore, a first servo motor is also provided in the flat punching module. The first servo motor is connected to a third encoder for recording the rotational displacement value of the first servo motor. The first servo motor is used to drive the material section reaching the flat punching module to move. A second servo motor is also provided in the frame forming module. The second servo motor is connected to a fourth encoder for recording the rotational displacement value of the second servo motor. The second servo motor is used to drive the material section reaching the frame forming module to move; a first buffer storage area is also provided between the uncoiling module and the flat punching module, and a second buffer storage area is also provided between the flat punching module and the frame forming module; the automatic control method further includes:

[0102] Judge whether the reading of the first encoder and the reading of the third encoder are within the first preset range at the same time. If not, an alarm for abnormal conveying is given;

[0103] Judge whether the reading of the second encoder and the reading of the fourth encoder are within the second preset range at the same time. If not, an alarm for abnormal conveying is given;

[0104] When the second induction signal sent by the first buffer zone is obtained, stop the pulling and conveying of the material section by the flat punching module, and when the third induction signal sent by the first buffer zone is obtained, stop the feeding of the uncoiling module, where the second induction signal is generated when the material section touches the upper limit position of the first buffer zone, and the third induction signal is generated when the material section touches the lower limit position of the first buffer zone;

[0105] When the fourth induction signal sent by the second buffer zone is obtained, stop the pulling and conveying of the material section by the frame forming module, and when the fifth induction signal sent by the second buffer zone is obtained, stop the output of the material section by the flat punching module, where the fourth induction signal is generated when the material section touches the upper limit position of the second buffer zone, and the fifth induction signal is generated when the material section touches the lower limit position of the second buffer zone.

[0106] Furthermore, a second photoelectric switch is also provided in the frame forming module, and the second photoelectric switch is arranged between the first photoelectric switch and the flat punching module; the production bill of materials also includes the length data of the material section; the automatic control method further includes:

[0107] Obtain the sixth induction signal generated after the second photoelectric switch is triggered. After obtaining the sixth induction signal, decelerate the transmission section between the frame forming module and the forming stamping module, where when the process hole reaches the position of the second photoelectric switch, the second photoelectric switch is triggered to generate the sixth induction signal;

[0108] Judge whether the difference between the absolute value of the difference between two adjacent second readings obtained and the length data of the material section is within the third preset range. If not, give an alarm for abnormal length of the material section.

[0109] Embodiment III

[0110] This embodiment provides a device, which includes a PLC controller and an industrial control screen. The PLC controller is connected to the industrial control screen. All instruction sets of the uncoiling control module, the first buffer control module, the first conveying control module, the flat punching control module, the second buffer control module, the second conveying control module, the forming control module, the process hole detection module, the forming stamping control module and the retracting control module implemented in Embodiment I are loaded into the PLC controller to realize the automatic control of the door frame production equipment in Embodiment I.

[0111] The above are only the preferred embodiments of the present invention. It should be understood that the present invention is not limited to the forms disclosed herein, and should not be regarded as excluding other embodiments. Instead, it can be used in various other combinations, modifications, and environments, and can be changed within the scope of the concept described herein through the above teachings or the technology or knowledge in the relevant field. Any changes and variations made by those skilled in the art without departing from the spirit and scope of the present invention shall fall within the protection scope of the appended claims of the present invention.

Claims

1. An automatic control system applicable to the production of door frames, characterized in that, Applied to the door frame production equipment, the door frame production equipment includes an uncoiling module, a flat punching module, a frame forming module, a retracting module, and a forming stamping module provided with an embossing die. Each embossing die is provided with an embossing hole one by one. A first encoder, a flat punching die, and a process hole die are arranged in the flat punching module. The process hole die is arranged between the uncoiling module and the flat punching die. A second encoder and a first photoelectric switch are arranged in the frame forming module. The first encoder and the second encoder are used to record position values; The automatic control system includes: An uncoiling control module, connected to the uncoiling module, for controlling the feeding action of the uncoiling module; A flat punching control module, connected to the flat punching module, for controlling the process hole die to open a process hole for the material section reaching the process hole die, and then obtaining a first reading and a production bill of materials, and determining a first position value according to the first reading and the production bill of materials. The first position value is the reading of the first encoder when the material section reaching the process hole die is moved to each flat punching corresponding to the flat punching die, so that the material section is shifted according to each determined first position value, and then the flat punching die corresponding to the first position value performs the punching action of the corresponding flat punching on the material section. The first reading is the reading of the first encoder when the material section released by the uncoiling module is moved to the process hole die; A forming control module, connected to the frame forming module, for performing process control on the forming action, and the forming action is the action performed by the frame forming module on the material section after flat punching; A process hole detection module, connected to the first photoelectric switch and the second encoder, for obtaining a second reading and a first induction signal generated after the first photoelectric switch is triggered. The second reading is the reading of the second encoder when the first photoelectric switch generates the first induction signal. Wherein, when the process hole reaches the position of the first photoelectric switch, the first photoelectric switch is triggered to generate the first induction signal; A forming stamping control module, connected to the forming stamping module, for obtaining the second reading and the production bill of materials, and then determining a second position value according to the second reading and the production bill of materials. The second position value is the reading of the second encoder when the formed material section is moved to the embossing die corresponding to each embossing hole, so that the formed material section is shifted according to each determined second position value, and the embossing die corresponding to the second position value performs the embossing action of the corresponding embossing hole on the formed material section; A retracting control module, connected to the retracting module, for controlling the retracting module to perform a shearing action, and the shearing action is to cut off the waste material and the process hole in the embossed material section; Wherein, the production bill of materials includes the distance values between each pre-opened flat punching and the process hole of the material section, and the distance values between each pre-opened embossing hole and the process hole of the material section.

2. The automatic control system applicable to the production of door frames according to claim 1, characterized in that, A first servo motor is further arranged in the flat punching module. The first servo motor is connected with a third encoder for recording the rotational displacement value of the first servo motor. The first servo motor is used to drive the movement of the material section reaching the flat punching module. A second servo motor is further arranged in the frame forming module. The second servo motor is connected with a fourth encoder for recording the rotational displacement value of the second servo motor. The second servo motor is used to drive the movement of the material section reaching the frame forming module. The automatic control system further includes: A first conveying control module, connected to the first encoder and the first servo motor, is used to judge whether the readings of the first encoder and the third encoder are within a first preset range at the same moment. If not, an abnormal conveying alarm is given. A second conveying control module, connected to the second encoder and the second servo motor, is used to judge whether the readings of the second encoder and the fourth encoder are within a second preset range at the same moment. If not, an abnormal conveying alarm is given.

3. The automatic control system applicable to the production of door frames according to claim 1, characterized in that, A first buffer zone is further arranged between the uncoiling module and the flat punching module, and a second buffer zone is further arranged between the flat punching module and the frame forming module. The automatic control system further includes: A first buffer control module, connected to the first buffer zone, is used to stop the pulling and conveying of the material section by the flat punching module when obtaining a second induction signal sent by the first buffer zone, and to stop the uncoiling of the uncoiling module when obtaining a third induction signal sent by the first buffer zone. Among them, the second induction signal is generated when the material section touches the upper limit position of the first buffer zone, and the third induction signal is generated when the material section touches the lower limit position of the first buffer zone. A second buffer control module, connected to the second buffer zone, is used to stop the pulling and conveying of the material section by the frame forming module when obtaining a fourth induction signal sent by the second buffer zone, and to stop the output of the material section by the flat punching module when obtaining a fifth induction signal sent by the second buffer zone. Among them, the fourth induction signal is generated when the material section touches the upper limit position of the second buffer zone, and the fifth induction signal is generated when the material section touches the lower limit position of the second buffer zone.

4. The automatic control system applicable to the production of door frames according to claim 1, characterized in that, A second photoelectric switch is further arranged in the frame forming module. The second photoelectric switch is arranged between the first photoelectric switch and the flat punching module. The process hole detection module is further connected to the second photoelectric switch and is used to obtain a sixth induction signal generated after the second photoelectric switch is triggered. After obtaining the sixth induction signal, the transmission section between the frame forming module and the forming stamping module is decelerated. Among them, when the process hole reaches the position of the second photoelectric switch, the second photoelectric switch is triggered to generate the sixth induction signal.

5. The automatic control system applicable to the production of door frames according to claim 1, characterized in that, The automatic control system further includes a host computer, and the host computer is respectively connected to the uncoiling control module, the flat punching control module, the forming control module, the process hole detection module, the forming stamping control module and the retracting control module.

6. The automatic control system applicable to the production of door frames according to claim 1, characterized in that, The production material list further includes the length data of the material section; the process hole detection module is further configured to determine whether the difference between the absolute value of the difference between two adjacent second readings obtained and the length data of the material section is within a third preset range. If not, an alarm for abnormal material section length is given.

7. The automatic control system applicable to the production of door frames according to claim 1, characterized in that, The uncoiling control module is further configured to obtain the remaining material characteristic parameters of the uncoiling module, and determine whether there is material in the uncoiling module according to the remaining material characteristic parameters. If not, a no-material alarm is given.

8. An automatic control method applicable to the production of door frames, characterized in that, Applied to a door frame production device, the door frame production device includes an uncoiling module, a flat punching module, a frame forming module, a retracting module, and a forming and stamping module provided with an embossing die. Each embossing die is provided with each embossing hole correspondingly. A first encoder, a flat punching die, and a process hole die are arranged in the flat punching module. The process hole die is arranged between the uncoiling module and the flat punching die. A second encoder and a first photoelectric switch are arranged in the frame forming module. The first encoder and the second encoder are used to record position values. The automatic control method includes: Controlling the feeding action of the uncoiling module, obtaining the remaining material characteristic parameters of the uncoiling module, and determining whether there is material in the uncoiling module according to the remaining material characteristic parameters. If not, a no-material alarm is given; Controlling the process hole die to open a process hole in the material section reaching the process hole die, then obtaining a first reading and a production material list, and determining a first position value according to the first reading and the production material list. The first position value is the reading of the first encoder when the material section reaching the process hole die is moved to each flat punching die corresponding to the flat punching. So that the material section is shifted according to each determined first position value, and then the flat punching die corresponding to the first position value performs the punching action of the corresponding flat punching on the material section. The first reading is the reading of the first encoder when the material section released by the uncoiling module is moved to the process hole die; Controlling the process of the forming action, where the forming action is the action performed by the frame forming module on the material section after flat punching; Obtaining a first induction signal and a second reading generated after the first photoelectric switch is triggered. The second reading is the reading of the second encoder when the first photoelectric switch generates the first induction signal. Wherein, when the process hole reaches the position of the first photoelectric switch, the first photoelectric switch is triggered to generate the first induction signal; Obtaining the second reading and the production material list, and then determining a second position value according to the second reading and the production material list. The second position value is the reading of the second encoder when the formed material section is moved to each embossing die corresponding to the embossing hole. So that the formed material section is shifted according to each determined second position value, and the embossing die corresponding to the second position value performs the embossing action of the corresponding embossing hole on the formed material section; Controlling the retracting module to perform a shearing action, where the shearing action is to cut off the waste material and the process hole in the embossed material section; Wherein, the production material list includes the distance values between each pre-opened flat punching hole and the process hole of the material section, and the distance values between each pre-opened embossing hole and the process hole of the material section.

9. The automatic control method applicable to door frame production according to claim 8, characterized in that, A first servo motor is further provided in the flat punching module. The first servo motor is connected to a third encoder for recording the rotational displacement value of the first servo motor. The first servo motor is used to drive the movement of the material section reaching the flat punching module. A second servo motor is further provided in the frame forming module. The second servo motor is connected to a fourth encoder for recording the rotational displacement value of the second servo motor. The second servo motor is used to drive the movement of the material section reaching the frame forming module. A first buffer area is further provided between the uncoiling module and the flat punching module, and a second buffer area is further provided between the flat punching module and the frame forming module. The automatic control method further includes: judging whether the readings of the first encoder and the third encoder are within a first preset range at the same moment. If not, an abnormal conveying alarm is given. judging whether the readings of the second encoder and the fourth encoder are within a second preset range at the same moment. If not, an abnormal conveying alarm is given. When the second induction signal sent by the first buffer area is obtained, the pulling and conveying of the material section by the flat punching module is stopped, and when the third induction signal sent by the first buffer area is obtained, the uncoiling of the uncoiling module is stopped, where the second induction signal is generated when the material section touches the upper limit position of the first buffer area, and the third induction signal is generated when the material section touches the lower limit position of the first buffer area. When the fourth induction signal sent by the second buffer area is obtained, the pulling and conveying of the material section by the frame forming module is stopped, and when the fifth induction signal sent by the second buffer area is obtained, the output of the material section by the flat punching module is stopped, where the fourth induction signal is generated when the material section touches the upper limit position of the second buffer area, and the fifth induction signal is generated when the material section touches the lower limit position of the second buffer area.

10. The automatic control method applicable to the production of door frames according to claim 8, characterized in that, A second photoelectric switch is further provided in the frame forming module. The second photoelectric switch is arranged between the first photoelectric switch and the flat punching module. The production material list further includes the length data of the material section. The automatic control method further includes: obtaining a sixth induction signal generated after the second photoelectric switch is triggered. After the sixth induction signal is obtained, the transmission section between the frame forming module and the forming stamping module is decelerated, where the second photoelectric switch is triggered to generate the sixth induction signal when the process hole reaches the position of the second photoelectric switch. judging whether the absolute value of the difference between two adjacent second readings obtained and the difference between the length data of the material section are within a third preset range. If not, an abnormal material section length alarm is given.

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