A device and method for automatically unloading residual rolls

Abstract

The application relates to a device and a method for automatically unloading a residual coil, which comprises a coil trolley, an uncoiler, an inlet guide roller, a supporting roller, a head cutting shear, a strip detection unit, a distance detection unit, a contact detection unit and a control unit. The coil trolley is used for loading and unloading the coil. The contact detection unit is installed on the saddle of the coil trolley and used for detecting whether the trolley is in contact with the coil. The distance detection unit is arranged on the coil trolley and used for detecting the lifting distance of the coil trolley. The uncoiler is provided with an encoder motor and a transmission device. The strip detection unit is used for detecting the strip. The control unit is electrically connected with the strip detection unit, the distance detection unit, the contact detection unit and the encoder, used for calculating the data required for the uncoiler to rewind according to the detection signals, and controlling the uncoiler to rewind correspondingly, so as to realize the winding of the strip. The device and the method have high automation degree, can not only save the labor and time cost, improve the work efficiency, but also improve the reliability of the residual coil unloading work.

Description

Technical Field

[0001] This invention relates to the field of metal strip processing technology, and specifically to an automatic device and method for unloading residual coils. Background Technology

[0002] In existing technology, the unwinding of residual coils during aluminum strip processing is manually controlled by a control button to reverse the uncoiler. Simultaneously, the unwinding trolley and pressure rollers are used to rewind the strip head back to the uncoiler and stop it at approximately the 7 o'clock position. This method not only wastes time and reduces efficiency, increasing waiting time for the next process such as unwinding and strip beating, but also leads to equipment damage due to improper operation, such as broken uncoiler mandrels and broken pressure rollers. Summary of the Invention

[0003] The purpose of this invention is to provide an automatic device and method for unloading residual rolls. This device and method have a high degree of automation, which not only saves manpower and time costs and improves work efficiency, but also improves the reliability of unloading residual rolls.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is: an automatic unloading device for residual coils, comprising a coil trolley, an uncoiler, an inlet guide roller, an idler roller, and a cutting shear; further comprising a strip detection unit, a distance detection unit, a contact detection unit, and a control unit. The coil trolley, through its lifting movement, loads the coil onto the uncoiler or unloads the residual coil from the uncoiler. The contact detection unit is mounted on a saddle on the upper part of the coil trolley for contacting the coil, used to detect whether the trolley is in contact with the coil. The distance detection unit is configured on the coil trolley. The uncoiler is used to detect the distance of the roll trolley's lifting and lowering; the uncoiler is equipped with a motor and transmission device with an encoder, which controls the motor to rotate through the encoder, and then drives the uncoiler to rotate through the transmission device; the strip detection unit is set between the inlet guide roller and the cutter shear, and is used to detect the strip; the control unit is electrically connected to the strip detection unit, the distance detection unit, the contact detection unit and the encoder respectively, and is used to calculate the data that the uncoiler needs to rewind according to the detection signals of each detection unit, and control the uncoiler to rewind the corresponding number of turns and angle, so as to realize the strip winding.

[0005] Furthermore, the uncoiler is used to unwind the strip from a coil into a strip. The installation height of the uncoiler is lower than the inlet guide roller. The inlet guide roller is used to guide the unwound strip to a horizontal position and then guide it through several idler rollers to the cutting head shear. The cutting head shear is used to cut the strip.

[0006] Furthermore, the strip detection unit is a photoelectric switch.

[0007] Furthermore, the distance detection unit is a wire encoder.

[0008] Furthermore, the contact detection unit is an ultrasonic sensor.

[0009] Furthermore, the control unit is a PLC control device.

[0010] The present invention also provides a method for automatically unloading residual rolls based on the above-described device, comprising:

[0011] 1) When the control unit receives a command to unload the residual roll, it controls the cutting head shear to cut the strip;

[0012] 2) The control unit controls the uncoiler to rewind. When the strip detection unit detects the strip head, that is, when it suddenly changes from detecting the strip to not detecting the strip, the control unit controls the uncoiler to stop rewinding.

[0013] 3) The control unit controls the roll trolley to rise until it touches the roll. Then, it calculates the radius of the current roll by the distance the roll trolley has risen, as detected by the distance detection unit. It also calculates the length of the strip from the strip detection unit position to the set position on the uncoiler, and then calculates the number of turns and angle that the uncoiler needs to rewind the strip of that length.

[0014] 4) After the above calculations are completed, the control unit uses the encoder and motor to precisely control the unwinder to continue rewinding the required number of turns and angle.

[0015] 5) When the number of rewinding turns and the angle of the uncoiler reach the requirements, the control unit controls the motor to stop working and completes the strip winding.

[0016] Furthermore, the distance detection unit detects the distance h that the roll trolley rises and transmits the detection data to the control unit. The control unit calculates the radius R = H – h of the current roll based on the predetermined distance H between the saddle and the center of the uncoiler before the roll trolley rises and the received distance h.

[0017] The length L of the strip from the strip detection unit to the set winding position on the uncoiler is:

[0018] L≈L1+L2+L3

[0019] In the formula, L1 is the distance of the strip from the strip detection unit to the inlet guide roller, L2 is the distance of the strip from the inlet guide roller to the tangent point of the outer circle of the coil, and L3 is the distance of the strip from the tangent point of the outer circle of the coil to the set winding position; the formula for calculating L2 is:

[0020]

[0021] In the formula, d is the distance from the center of the uncoiler to the upper quadrant point of the inlet guide roller, and R is the radius of the current coil.

[0022] Taking the point symmetrical about the center of the uncoiler with respect to the outer tangent of the roll material as the set winding position, the formula for calculating L3 is:

[0023] L3=πR

[0024] Thus, the length L is obtained as:

[0025]

[0026] The total angle θ that the uncoiler needs to rewind for a strip of length L is:

[0027] θ = n × 360° + θ1

[0028] In the formula, θ1 is the angle that the uncoiler needs to rotate to send the remaining strip to the set winding position after the uncoiler has rotated n times, and n is the number of full turns that the uncoiler needs to rewind. The calculation formula is as follows:

[0029]

[0030] Then, the remaining strip length L4 after the uncoiler has completed n revolutions is:

[0031] L4=L-2nπR

[0032] The angle θ1 required to rotate the remaining strip to the designated winding position is:

[0033]

[0034] Furthermore, the strip detection unit is in a closed state when the system is performing normal unwinding or not working. When the cutting shear is cutting the strip or the unwinder is rewinding, the control unit controls the strip detection unit to switch to working state to detect the strip.

[0035] Compared with existing technologies, the present invention has the following advantages: It provides an automatic strip unwinding device and method. This device detects relevant signals by setting up a strip detection unit, a distance detection unit, and a contact detection unit. A control unit accurately calculates the data that the uncoiler needs to rewind. Based on this, an encoder precisely controls the uncoiler to rewind the corresponding number of turns and angle, thereby achieving automatic strip unwinding. This device and method have a high degree of automation, requiring no manual operation, saving manpower and time costs, and improving the convenience and efficiency of strip unwinding. At the same time, by eliminating manual operation, it avoids equipment damage that may be caused by improper human operation, improving the reliability and safety of strip unwinding. Therefore, the present invention has strong practicality and broad application prospects. Attached Figure Description

[0036] Figure 1 This is a schematic diagram illustrating the implementation principle of the apparatus and method according to an embodiment of the present invention. Detailed Implementation

[0037] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0038] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0039] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0040] like Figure 1 As shown, this embodiment provides an automatic unloading device for residual coils, including a coil trolley 1, an uncoiler 2, an inlet guide roller 3, an idler roller 4, a cutting shear 5, a strip detection unit 6, a distance detection unit 7, a contact detection unit 8, and a control unit. The coil trolley 1 uses its lifting movement to mount the coil 9 onto the uncoiler 2 or unload residual coils from the uncoiler. The contact detection unit 8 is mounted on a saddle on the upper part of the coil trolley 1 for contacting the coil, used to detect whether the trolley is in contact with the coil. The distance detection unit 7 is configured on the coil trolley 1 for... The uncoiler 2 is equipped with a motor and a transmission device with an encoder, which controls the motor to rotate via the encoder and then drives the uncoiler to rotate via the transmission device. The strip detection unit 6 is located between the inlet guide roller and the cutter head and is used to detect the strip. The control unit is electrically connected to the strip detection unit 6, the distance detection unit 7, the contact detection unit 8 and the encoder, respectively, and is used to calculate the data that the uncoiler needs to rewind based on the detection signals of each detection unit, and control the uncoiler to rewind the corresponding number of turns and angle to realize the strip winding.

[0041] The uncoiler 2 is used to unwind the strip from a coil into a strip, and the installation height of the uncoiler 2 is lower than that of the inlet guide roller. The inlet guide roller 3 is used to guide the unwound strip horizontally and then guides it to the cutter 5 via several idler rollers 4. The inlet guide roller 3 can be either an active roller or a passive roller. The cutter 5 is used to cut the strip, and can be hydraulically controlled or driven by a motor.

[0042] In this embodiment, the distance detection unit 7 is a pull-wire encoder. The pull-wire encoder includes an encoder and a puller. The encoder is installed at the bottom of the roll trolley, and the puller and encoder are connected by a coupling. The retaining ring of the puller is installed on the side of the saddle of the roll trolley. When the roll trolley rises with the saddle, the pull ring pulls the puller, thereby driving the encoder to rotate. The measurement is performed using the pulse count of the encoder.

[0043] In this embodiment, the strip detection unit 6 is a photoelectric switch. The contact detection unit 8 is an ultrasonic sensor. The control unit is a PLC control device. The PLC control device can be a Siemens 400 series or similar, used for logic calculation and control of the device operation, and the initial values ​​of constants such as L1, L0, and H can be set in the PLC.

[0044] This embodiment also provides a method for automatically unloading residual rolls based on the above-described device, including:

[0045] 1) When the control unit receives a command to unload the residual roll, it controls the cutting head shear to cut the strip.

[0046] 2) The control unit controls the uncoiler to rewind. When the strip detection unit detects the strip head, that is, when it suddenly changes from detecting the strip to not detecting the strip, the control unit controls the uncoiler to stop rewinding.

[0047] 3) The control unit controls the roll trolley to rise until it touches the roll. Then, it calculates the radius of the current roll by the distance the roll trolley has risen, as detected by the distance detection unit. It also calculates the length of the strip from the strip detection unit position to the set position on the uncoiler, and then calculates the number of turns and angle that the uncoiler needs to rewind the strip of that length.

[0048] 4) After the above calculations are completed, the control unit uses the encoder and motor to precisely control the unwinder to continue rewinding the required number of turns and angle.

[0049] 5) When the number of rewinding turns and the angle of the uncoiler reach the requirements, the control unit controls the motor to stop working and completes the strip winding.

[0050] Specifically, the distance detection unit detects the distance h that the roll trolley has risen and transmits the detection data to the control unit. The distance H between the saddle and the center of the uncoiler before the roll trolley rises is a fixed height; this value is determined and stored in the control unit after the device design and installation are completed. The control unit calculates the current roll radius R = H – h based on the predetermined distance H between the saddle and the center of the uncoiler before the roll trolley rises and the received distance h.

[0051] The length L of the strip from the strip detection unit to the set winding position on the uncoiler is:

[0052] L≈L1+L2+L3

[0053] In the formula, L1 is the distance of the strip from the strip detection unit to the inlet guide roller, L2 is the distance of the strip from the inlet guide roller to the tangent point on the outer circle of the coil, and L3 is the distance of the strip from the tangent point on the outer circle of the coil to the set winding position. The tangent point on the outer circle of the coil refers to the point where the inlet guide roller and the tangent line on the outer circle of the coil are tangent on the outer circle of the coil.

[0054] The formula for calculating L2 is as follows:

[0055]

[0056] In the formula, d is the distance from the center of the uncoiler to the upper quadrant point of the inlet guide roller, and R is the radius of the current coil.

[0057] It's important to note that in practice, L > L1 + L2 + L3. This is because, in addition to the distances L1, L2, and L3, L also includes the arc length on the outer circumference of the coil from the upper quadrant point of the inlet guide roller to the point where the tangent between the inlet guide roller and the outer circumference of the coil is tangent at the inlet guide roller. However, since this arc length is very short and has little impact on the overall calculation result or the final winding position of the strip, it is ignored for ease of calculation, and we directly set L ≈ L1 + L2 + L3. Furthermore, in practice... To be precise, L2 should be the length of the tangent between the inlet guide roller and the outer circle of the coil. For ease of calculation, the point of tangency between the inlet guide roller and the outer circle of the coil at the inlet guide roller is taken as the upper quadrant point of the inlet guide roller. The two approximations cancel each other out, making the calculated result of L closer to the actual result.

[0058] In this embodiment, the winding position is set at the point symmetrical about the outer circle tangent of the roll material with respect to the center of the uncoiler (approximately 7 o'clock). The formula for calculating L3 is as follows:

[0059] L3=πR

[0060] Thus, the length L is obtained as:

[0061]

[0062] The total angle θ that the uncoiler needs to rewind for a strip of length L is:

[0063] θ = n × 360° + θ1

[0064] In the formula, θ1 is the angle that the uncoiler needs to rotate to send the remaining strip to the set winding position after the uncoiler has rotated n times, and n is the number of full turns that the uncoiler needs to rewind. The calculation formula is as follows:

[0065]

[0066] Then, the remaining strip length L4 after the uncoiler has completed n revolutions is:

[0067] L4=L-2nπR

[0068] The angle θ1 required to rotate the remaining strip to the designated winding position is:

[0069]

[0070] Preferably, the strip detection unit is in a closed state when the system is performing normal unwinding or not working. When the cutting shear is cutting the strip or the unwinder is rewinding, the control unit controls the strip detection unit to switch to working state to detect the strip.

[0071] from Figure 1 It is easy to see that when the uncoiler is designed below the guide roller, whether at the maximum uncoiling diameter or the minimum uncoiling diameter (dmin), the reverse extension line connecting the strip at the point of tangency between the inlet guide roller and the outer circle of the coil on the outer circle of the coil is approximately at the 7 o'clock position, forming a certain angle. It can be deduced that for any coil within the range of the minimum and maximum uncoiling diameters, the reverse extension line at the point of tangency on the outer circle of the coil can be considered to meet the requirements. Practical experience has proven that this meets the requirements for production use.

[0072] After the winding process is completed, the encoder value of the uncoiler motor is reset to zero (to prevent the engineering value from overflowing) for the next operation. Then, the next process such as unwinding and tape wrapping can be performed.

[0073] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A method for automatically unloading residual rolls, characterized in that, An automatic unloading device for residual coils is provided, including a coil trolley, an uncoiler, an inlet guide roller, an idler roller, a cutter, a strip detection unit, a distance detection unit, a contact detection unit, and a control unit. The coil trolley, through its lifting and lowering movement, loads the coil onto the uncoiler or unloads the residual coil from the uncoiler. The contact detection unit is mounted on a saddle on the upper part of the coil trolley for contacting the coil, and is used to detect whether the trolley is in contact with the coil. The distance detection unit is configured on the coil trolley for detecting the lifting distance of the coil trolley. The uncoiler is equipped with a motor with an encoder and a transmission device, for controlling the motor rotation via the encoder, and then driving the uncoiler rotation via the transmission device. The strip detection unit is located between the inlet guide roller and the cutter, and is used to detect the strip. The control unit is electrically connected to the strip detection unit, the distance detection unit, the contact detection unit, and the encoder, and is used to calculate the data that the uncoiler needs to rewind based on the detection signals of each detection unit, and control the uncoiler to rewind the corresponding number of turns and angle, thereby realizing the strip winding. The uncoiler is used to unwind the strip from a coil into a strip. The installation height of the uncoiler is lower than the inlet guide roller. The inlet guide roller is used to guide the unwound strip to a horizontal position and then guide it through several idler rollers to the cutting head shear. The cutting head shear is used to cut the strip. The strip detection unit is a photoelectric switch; The distance detection unit is a wire encoder; The contact detection unit is an ultrasonic sensor; The control unit is a PLC control device; The method for automatically unloading residual rolls includes: 1) When the control unit receives a command to unload the residual roll, it controls the cutting head shear to cut the strip; 2) The control unit controls the uncoiler to rewind. When the strip detection unit detects the strip head, that is, when it suddenly changes from detecting the strip to not detecting the strip, the control unit controls the uncoiler to stop rewinding. 3) The control unit controls the roll trolley to rise until it touches the roll. Then, it calculates the radius of the current roll by the distance the roll trolley has risen, as detected by the distance detection unit. It also calculates the length of the strip from the strip detection unit position to the set position on the uncoiler, and then calculates the number of turns and angle that the uncoiler needs to rewind the strip of that length. 4) After the above calculations are completed, the control unit uses the encoder and motor to precisely control the unwinder to continue rewinding the required number of turns and angle. 5) When the number of rewinding turns and the angle of the uncoiler reach the requirements, the control unit controls the motor to stop working, and the strip is rewound. The distance detection unit detects the distance h that the roll trolley rises and transmits the detection data to the control unit. The control unit calculates the radius R = H – h of the current roll based on the predetermined distance H between the saddle and the center of the uncoiler before the roll trolley rises and the received distance h. The length L of the strip from the strip detection unit to the set winding position on the uncoiler is: In the formula, L1 is the distance of the strip from the strip detection unit to the inlet guide roller, L2 is the distance of the strip from the inlet guide roller to the tangent point of the outer circle of the coil, and L3 is the distance of the strip from the tangent point of the outer circle of the coil to the set winding position; the formula for calculating L2 is: In the formula, d is the distance from the center of the uncoiler to the upper quadrant point of the inlet guide roller, and R is the radius of the current coil. Taking the point symmetrical about the center of the uncoiler with respect to the outer tangent of the roll material as the set winding position, the formula for calculating L3 is: Thus, the length L is obtained as: The total angle θ that the uncoiler needs to rewind for a strip of length L is: In the formula, θ1 is the angle that the uncoiler needs to rotate to send the remaining strip to the set winding position after the uncoiler has rotated n times, and n is the number of full turns that the uncoiler needs to rewind. The calculation formula is as follows: Then, the remaining strip length L4 after the uncoiler has completed n revolutions is: The angle θ1 required to rotate the remaining strip to the designated winding position is: The strip detection unit is in a closed state when the system is performing normal unwinding or not working. When the cutting shear is cutting the strip or the unwinder is rewinding, the control unit controls the strip detection unit to switch to working state to detect the strip.

Images