A forging step beam servo control system and method

Abstract

The application discloses a kind of forging step beam servo control system and method, solve the problem of poor performance of prior art step beam control system, with better security, faster response speed Advantage, specific scheme is as follows: a kind of forging step beam servo control system, including industrial computer, controller, data acquisition module, control module, industrial computer is connected with controller, controller is separately connected with data acquisition module, motor control module, motor control module includes driver and motor, driver is connected with motor, motor is connected with ball screw mechanism to distinguish step beam or gripper;Industrial computer is installed with the motion control software for parameter setting and motor motion control program writing;Controller receives instruction from industrial computer and real-time information transmitted by data acquisition module and handles, judges the state and position of motor, compares with motor setting track, state, finally transmits real-time monitoring information to industrial computer.

Description

Technical Field

[0001] This invention relates to the field of forging production technology, and in particular to a servo control system and method for forging walking beams. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] Forging is a fundamental process in machinery manufacturing. Forging effectively eliminates internal defects and improves the mechanical properties of metallic materials. Therefore, important and critical mechanical components generally require forging. However, forging operations present significant health risks to operators due to insurmountable high temperatures, dust, noise, and vibration. Automation of forging production has become an inevitable trend in the industry. Coupled with rising labor costs, intelligent manufacturing has become a development direction and a major development strategy for China's manufacturing sector.

[0004] Forging servo stepper beams are specialized equipment for high-end forging automation, suitable for large-batch, multi-station continuous forging production. They offer significant advantages such as greatly improved production efficiency, reduced labor, and lower production costs. Their efficiency is 2-3 times that of ordinary robots, while their price is only 1 / 2 to 2 / 3 of that of robots, making them a key core piece of equipment for the industry's development. The servo stepper beam is the main device for component transmission at the main workstation of an automated forging line. This structure boasts advantages such as high synchronization, fast transmission speed, and small footprint.

[0005] The forging servo stepping beam can realize automated gripping of forgings and continuous forging in multiple stations. Through steps such as clamping and lifting, advancing, lowering and opening, and in conjunction with the movement of the slider, it completes the continuous forging process of billet pre-upsetting, upsetting, pre-forging, final forging and punching.

[0006] The inventors discovered that the main problems with forged servo stepper beams are:

[0007] The feeding device moved, causing an error, which resulted in the gripper at the first station of the walking beam failing to pick up the bar stock.

[0008] Material falls out during the process of the gripper moving the material to the next station;

[0009] The material release position shifts during the process of the gripper moving the material to the next station.

[0010] The above problems are mainly caused by the poor performance of the servo control system. Summary of the Invention

[0011] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a servo control system for forging walking beams, which improves the stability of the grippers during the forging process and ensures the continuous and controllable forging operation.

[0012] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0013] A servo control system for forging stepping beams includes an industrial computer, a controller, a data acquisition module, and a control module. The industrial computer is connected to the controller, and the controller is separately connected to the data acquisition module and the motor control module. The motor control module includes a driver and a motor. The driver is connected to the motor, and the motor is connected to a ball screw mechanism to drive the stepping beam or gripper.

[0014] The industrial computer is equipped with motion control software for parameter setting and motor motion control program writing; the controller receives and processes instructions from the industrial computer and real-time information transmitted by the data acquisition module, determines the motor's status and position, compares it with the motor's set trajectory and status, and finally transmits the real-time monitoring information to the industrial computer. After the industrial computer makes corresponding adjustments to the motor trajectory and status, it sends enable control signals to the motor control module and the stepper beam control module, and transmits real-time monitoring signals to the industrial computer.

[0015] As described above, the servo control system for a forged walking beam includes a data acquisition module comprising an indicator light for indicating the current status of the motor, a push-button switch for controlling the start and stop of the motor, a displacement sensor for detecting the position of the walking beam, a speed sensor for detecting the motor speed, a temperature sensor for detecting the motor temperature, and an encoder mounted on the motor.

[0016] In the forging stepper beam servo control system described above, the displacement sensor is provided at the end of the stepper beam and gripper away from the motor, and the speed sensor and temperature sensor are installed on the motor.

[0017] As described above, in a forging walking beam servo control system, the controller obtains the various travel distances of the walking beam based on information from the displacement sensor, speed sensor, and temperature sensor, and transmits the signals to the industrial control computer so that the controller can adjust the motor status and the delay interval of the walking beam transport in a timely manner.

[0018] Secondly, the present invention also provides a servo control method for forging stepper beams, which employs the aforementioned servo control system for forging stepper beams. The controller adjusts the angular velocity and angular displacement of the motor in real time according to an improved active disturbance rejection control algorithm to achieve precise control of the stepper beam's movement speed and starting position.

[0019] The forging walking beam servo control method described above includes an improved active disturbance rejection algorithm that, based on the traditional nonlinear active disturbance rejection control algorithm, incorporates a nonlinear tracking differentiator, an extended state observer, and a nonlinear function. Improvements have been made.

[0020] As described above, in a servo control method for a forging walking beam, the improved active disturbance rejection algorithm eliminates the nonlinear tracking differentiator to reduce tuning difficulty and enhance dynamic response.

[0021] As described above, in a servo control method for forging walking beams, the improved active disturbance rejection algorithm employs a cascaded extended state observer composed of a first-level extended state observer and a second-level extended state observer. The cascaded extended state observer estimates and compensates for the total disturbance in the control system, thereby achieving rapid tracking of the total disturbance.

[0022] As described above, in a servo control method for forging walking beams, the improved active disturbance rejection algorithm optimizes the function. To avoid slow convergence when facing high error conditions;

[0023] The first-level extended state observer ESO1 is constructed as follows:

[0024]

[0025] in, and yes and Observed values; and yes and The differential; and This is the observer gain of ESO1; These are the observers The error between the predicted value and the set value; It is a nonlinear continuous function of the first-order extended state observer ESO1; It is a constant between 0 and 1; These are constants that affect the filtering effect; The gain of the input;

[0026] Observed by the first-level extended state observer ESO1 Considered a preliminary estimate and used as the known part of the second-level extended state observer ESO2, ESO2 is represented as follows:

[0027]

[0028] in, and It is the observer gain of the second-level extended state observer ESO2; yes The observed values, and have the same as The same function; and yes and The differential; Used for observation of residual perturbations; It is a nonlinear continuous function of ESO2; The controlled quantity;

[0029] Optimized nonlinear function The tuning difficulty is comparable to that of traditional nonlinear functions. Consistent;

[0030] ;

[0031] The tuning law for a cascaded extended state observer (CESO) consisting of a first-level extended state observer and a second-level extended state observer is:

[0032]

[0033] in It is the sampling period.

[0034] As described above, in a servo control method for a forging walking beam, the improved active disturbance rejection algorithm feeds back the conventional nonlinear state error and optimizes... The functions are combined to obtain the enhanced nonlinear state error feedback (NLSEF).

[0035] Enhanced Nonlinear State Error Feedback (NLSEF) is achieved through optimization. By combining current and observational information, error sensitivity and combinatorial diversity are significantly improved. The expression of the enhanced nonlinear state error feedback (NLSEF) is shown below:

[0036]

[0037] in, ; This is a system settings input; It is a nonlinear continuous function of NLSEF, and 0 < <1, yes Gain, >0, determined according to dynamic response requirements.

[0038] Furthermore, The expression is:

[0039] ;

[0040] in, for The symbolic function.

[0041] The beneficial effects of the present invention are as follows:

[0042] 1) This invention uses an industrial control computer to set motion control software. This software allows for parameter setting and motor motion control program writing, making the industrial control computer a real-time operating system and a high-performance servo motion controller. The controller then determines the motor's status and position based on information transmitted from the data acquisition module. This results in a system with better safety, faster system response, higher precision, and smaller errors, effectively reducing positional errors of the stepper beam during movement and significantly increasing the stability of the gripper, thereby ensuring supply security and reducing costs.

[0043] 2) The data acquisition module in this invention includes displacement sensors, speed sensors, temperature sensors and encoders, which helps the controller to adjust the angular velocity and angular displacement of the motor in real time based on the acquired data, so as to achieve precise control of the stepper beam's movement speed and starting position.

[0044] 3) In this invention, the controller, based on the traditional nonlinear improved active disturbance rejection control algorithm, eliminates the nonlinear tracking differentiator (NTD) to reduce tuning difficulty and enhance dynamic response; the extended state observer (ESO) is improved by designing a cascaded extended state observer (CESO) consisting of a first-stage extended state observer (ESO1) and a second-stage extended state observer (ESO2), which enhances estimation capability; and the nonlinear function is optimized. This avoids slow convergence speed when facing high error states; furthermore, the algorithm combines the conventional nonlinear state error feedback law with an optimized nonlinear function. By combining these methods, we obtain the enhanced nonlinear state error feedback (NLSEF), which improves the control combinatorial efficiency while also significantly enhancing error sensitivity and combinatorial diversity. Attached Figure Description

[0045] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0046] Figure 1 This is a flowchart illustrating the usage method of a forging stepping beam servo control system according to one or more embodiments of the present invention.

[0047] Figure 2 This is a structural block diagram of a forging stepping beam servo control system according to one or more embodiments of the present invention. Detailed Implementation

[0048] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0049] 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 scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. 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.

[0050] As described in the background section, existing technologies suffer from poor performance of stepper beam control systems. To address these issues, this invention proposes a servo control system for forging stepper beams.

[0051] Example 1

[0052] In a typical embodiment of the present invention, reference is made to Figure 2 As shown, a forging stepper beam servo control system includes an industrial computer, a controller, a data acquisition module, and a control module. The industrial computer is connected to the controller, and the controller is connected to the data acquisition module and the motor control module separately. The motor control module includes a driver and a motor. The driver is connected to the motor, and the motor is connected to a ball screw mechanism to drive the stepper beam or the gripper.

[0053] The industrial computer is equipped with motion control software for parameter setting and motor motion control program writing. The controller receives and processes instructions from the industrial computer and real-time information transmitted by the data acquisition module, determines the motor's state (speed, torque) and position, compares it with the motor's (speed, torque) set trajectory and state, and finally transmits the real-time monitoring information to the industrial computer. After the industrial computer makes corresponding adjustments to the motor trajectory and state (speed, torque), it sends enable control signals to the motor control module and the stepper beam control module, and transmits real-time monitoring signals to the industrial computer. The motion control software of the industrial computer can obtain the motor's torque information.

[0054] It needs to be explained that the motor includes multiple motors. Some motors are connected to the reducer, and the reducer is connected to the stepping beam through the transmission mechanism to control the forward or backward movement of the stepping beam. Some motors are connected to the ball screw mechanism, and the ball screw mechanism is connected to the stepping beam or the gripper to control the up and down movement of the stepping beam or the closing action of the gripper. The controller is connected to the motor and the reducer respectively. How the motor drives the stepping beam is existing technology and will not be described in detail here.

[0055] Specifically, the controller can be a PLC controller or other types of controllers, and the motion control software is TwinCAT3. This software can work completely independently of the hardware and runs on the same CPU as the controller. It converts the non-real-time kernel with Windows into a stable and efficient real-time operating system, controls the system using the EtherCAT (Ethernet for Control Automation Technology) protocol, connects the controller, drivers, various sensors, digital IO (Input and Output) modules, etc., to form a network, and sets up corresponding human-machine interaction application software to realize process control and process management visualization.

[0056] In addition, the motion control software Twin CAT3 can use more CPU, memory and other resources, supports and excels at various complex floating-point operations, can be programmed in a mixed manner with multiple languages ​​such as C++ and MATLAB, and supports mainstream buses such as EtherCAT, Profibus and CAN Open.

[0057] The motor is a three-phase asynchronous motor, specifically a three-phase asynchronous motor using the standard EtherCAT protocol bus. The driver is connected to the controller via a coupler module. The driver receives the enable signal from the TwinCAT PLC controller and transmits feedback signals to the TwinCAT PLC controller. The three-phase asynchronous motor is connected to the driver and receives control signals from the driver.

[0058] The data acquisition module includes indicator lights for indicating the current status of the motor, push-button switches for controlling the start and stop of the motor, displacement sensors for detecting the position of the stepper beam, speed sensors for detecting the motor speed, temperature sensors for detecting the motor temperature, and an encoder mounted on the motor. The data acquisition module also includes a digital input module (DI), a digital output module (DO), and an analog input module (AI), each module being connected to a corresponding sensor.

[0059] Understandably, a displacement sensor is installed at the end of the stepper beam and gripper away from the motor, and an encoder, speed sensor, and temperature sensor are installed on the motor. The displacement sensor, speed sensor, and temperature sensor all use existing displacement sensors, speed sensors, and temperature sensors. The encoder transmits the angular displacement information of the motor to the controller.

[0060] In addition, the controller obtains the travel distance of each step beam based on information from the displacement sensor, encoder, speed sensor, and temperature sensor, and transmits the signal to the industrial control computer so that the controller can adjust the motor status and the delay interval of the step beam transport in a timely manner.

[0061] A working method of a servo control system for a forging walking beam, with reference to Figure 1 As shown, it includes the following:

[0062] (1) Set the motor motion trajectory. Set the motor speed, step beam lifting stroke distance, step beam clamping stroke distance, step beam conveying stroke distance, stroke per minute, and delay interval of automated handling of forging equipment on the industrial control computer.

[0063] In case of production stoppage or malfunction, the push-button switch can be used for emergency stop, allowing operators to react quickly and reduce losses.

[0064] (2) Detect the action of the gripper, the action of the gripper, and the clamping of the gripper.

[0065] (3) Detect the position of the stepping beam. The stepping beam moves by first raising the stepping beam, then moving the stepping beam forward, and then lowering the stepping beam.

[0066] (4) Detect the action of the gripper, the gripper action, the gripper opens.

[0067] The method for detecting the position of the walking beam is to use a displacement sensor to detect the position of the walking beam.

[0068] The driving method for the stepper beam and gripper is as follows: a driver is used to drive a three-phase asynchronous motor, and the three-phase asynchronous motor and ball screw work together to complete the movement of the stepper beam and gripper.

[0069] (5) At the end of the stroke, the controller judges whether the trajectory and movement of the stepping beam and the gripper are normal based on the real-time information transmitted by the data acquisition module. If normal, the stepping beam moves backward; if not normal, the controller makes appropriate adjustments on the industrial control computer in time and then moves the stepping beam backward.

[0070] (6) After the stepping beam moves backward, the operator should judge in advance whether the stepping beam has finished working. If it has finished working, press the stop switch and the action ends; if it has not finished working, continue to execute step (2).

[0071] The control system provided in this embodiment uses motion control software to achieve more direct and faster data exchange between motion control and logic control. Based on a full understanding of the running characteristics and motion model of the walking beam, it can reasonably determine the motion trajectory of the walking beam and the gripper, as well as the action trajectory of the gripper, according to the specific forging process. It can accurately control the overall speed and starting position of the walking beam, improve the stability of the gripper in the forging process, and ensure the continuous and controllable forging operation.

[0072] Example 2

[0073] A servo control method for forging stepper beams is provided, which adopts a servo control system for forging stepper beams as described in Embodiment 1. The system employs a dual-loop control structure, in which the controller drives the motor to control the inner loop and the industrial control computer controls the outer loop through the running trajectory. The controller adjusts the angular velocity and angular displacement of the motor in real time according to an improved active disturbance rejection control algorithm to achieve precise control of the stepper beam's movement speed and starting position.

[0074] It needs to be explained that the dual-loop control structure, which uses a controller to drive the motor to control the inner loop and an industrial computer to control the outer loop through the running trajectory, means that the controller controls the motor through the driver to achieve inner loop control. The controller compares the motor position with the set motor trajectory and feeds the feedback to the industrial computer. The industrial computer adjusts the motor trajectory to achieve dual-loop control.

[0075] Specifically, the improved active disturbance rejection algorithm, based on the traditional nonlinear active disturbance rejection control algorithm, incorporates a nonlinear tracking differentiator, an extended state observer, and a nonlinear function. Improvements have been made.

[0076] The improved active disturbance rejection algorithm eliminates the nonlinear tracking differentiator to reduce tuning difficulty and enhance dynamic response. The discretized expression of the nonlinear tracking differentiator in the traditional active disturbance rejection algorithm is as follows:

[0077]

[0078] in, It is a set value; yes The tracking signal; yes The tracking signal; Indicates the sampling period; and It is an adjustable parameter.

[0079] The improved active disturbance rejection algorithm uses a cascaded extended state observer consisting of a first-level extended state observer and a second-level extended state observer to enhance the estimation capability. The cascaded extended state observer estimates and compensates for the total disturbance in the control system, thereby achieving rapid tracking of the total disturbance.

[0080] It needs to be explained that the improved active disturbance rejection algorithm optimizes the nonlinear function. To avoid slow convergence when facing high error conditions;

[0081] The first-level extended state observer ESO1 is constructed as follows:

[0082]

[0083] in, and yes and Observed values; and yes and The differential; and This is the observer gain of ESO1; These are the observers The error between the predicted value and the set value; It is a nonlinear continuous function of the first-order extended state observer ESO1; It is a constant between 0 and 1; These are constants that affect the filtering effect; The gain of the input;

[0084] Observed by the first-level extended state observer ESO1 Considered a preliminary estimate and used as the known part of the second-level extended state observer ESO2, ESO2 is represented as follows:

[0085]

[0086] in, and It is the observer gain of the second-level extended state observer ESO2; yes The observed values, and have the same as The same function; and yes and The differential; Used for observation of residual perturbations; It is a nonlinear continuous function of ESO2; The controlled quantity;

[0087] Optimized nonlinear function The tuning difficulty is comparable to that of traditional nonlinear functions. Consistent;

[0088] ;

[0089] The tuning law for a cascaded extended state observer (CESO) consisting of a first-level extended state observer and a second-level extended state observer is:

[0090]

[0091] in It is the sampling period.

[0092] Furthermore, the improved active disturbance rejection algorithm combines conventional nonlinear state error feedback with optimized... The functions are combined to obtain the enhanced nonlinear state error feedback (NLSEF).

[0093] Enhanced Nonlinear State Error Feedback (NLSEF) is achieved through optimization. Combining current and observational information significantly improves error sensitivity and combinatorial diversity. The expression of the enhanced nonlinear state error feedback (NLSEF) is shown below:

[0094]

[0095] in, ; This is a system settings input; It is a nonlinear continuous function of NLSEF, and 0 < <1, yes Gain, >0, determined according to dynamic response requirements.

[0096] Furthermore, The expression is:

[0097] ;

[0098] in, for The symbolic function.

[0099] The controller adjusts the motor's angular velocity and angular displacement in real time based on an improved active disturbance rejection control algorithm. This improved algorithm, building upon traditional nonlinear active disturbance rejection control algorithms, eliminates the nonlinear tracking differentiator (NTD) to reduce tuning difficulty and enhance dynamic response. The extended state observer (ESO) is improved by designing a cascaded extended state observer (CESO) consisting of a first-stage extended state observer (ESO1) and a second-stage extended state observer (ESO2), enhancing estimation capabilities. The nonlinear function is also optimized. This avoids slow convergence speed when facing high error states; furthermore, the algorithm also incorporates conventional nonlinear state error feedback with optimized nonlinear functions. By combining these methods, we obtain the enhanced nonlinear state error feedback (NLSEF), which improves the control combinatorial efficiency while also significantly enhancing error sensitivity and combinatorial diversity.

[0100] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A servo control system for a forging walking beam, characterized in that, It includes an industrial computer, a controller, a data acquisition module, and a control module. The industrial computer is connected to the controller, and the controller is connected to the data acquisition module and the motor control module separately. The motor control module includes a driver and a motor. The driver is connected to the motor, and the motor is connected to a ball screw mechanism to drive the stepping beam or gripper. The industrial computer is equipped with motion control software for parameter setting and motor motion control program writing; the controller receives and processes instructions from the industrial computer and real-time information transmitted by the data acquisition module, determines the motor's status and position, compares it with the motor's set trajectory and status, and finally transmits the real-time monitoring information to the industrial computer. After the industrial computer makes corresponding adjustments to the motor trajectory and status, it sends enable control signals to the motor control module and the stepper beam control module, and transmits real-time monitoring signals to the industrial computer. The first-level extended state observer ESO1 is constructed as follows: in, and yes and Observed values; and yes and The differential; and This is the observer gain of ESO1; These are the observers The error between the predicted value and the set value; It is a nonlinear continuous function of the first-order extended state observer ESO1; It is a constant between 0 and 1; These are constants that affect the filtering effect; The gain of the input; Observed by the first-level extended state observer ESO1 Considered a preliminary estimate and used as the known part of the second-level extended state observer ESO2, ESO2 is represented as follows: in, and It is the observer gain of the second-level extended state observer ESO2; yes The observed values, and have the same as The same function; and yes and The differential; Used for observation of residual perturbations; It is a nonlinear continuous function of ESO2; The controlled quantity; Optimized nonlinear function The tuning difficulty is comparable to that of traditional nonlinear functions Consistent; ； The tuning law for a cascaded extended state observer (CESO) consisting of a first-level extended state observer and a second-level extended state observer is: in It is the sampling period; The improved active disturbance rejection algorithm combines conventional nonlinear state error feedback with optimized... The functions are combined to obtain the enhanced nonlinear state error feedback (NLSEF). Enhanced Nonlinear State Error Feedback (NLSEF) is achieved through optimization. By combining current and observational information, error sensitivity and combinatorial diversity are significantly improved. The expression of the enhanced nonlinear state error feedback (NLSEF) is shown below: in, ; This is a system settings input; It is a nonlinear continuous function of NLSEF, and 0 < <1, yes Gain, >0, determined according to dynamic response requirements. Furthermore, The expression is: ； in, for The symbolic function.

2. The servo control system for a forging stepping beam according to claim 1, characterized in that, The data acquisition module includes an indicator light for indicating the current status of the motor, a push-button switch for controlling the start and stop of the motor, a displacement sensor for detecting the position of the stepper beam, a speed sensor for detecting the motor speed, a temperature sensor for detecting the motor temperature, and an encoder installed on the motor.

3. The forging stepping beam servo control system according to claim 2, characterized in that, The displacement sensor is located at the end of the stepper beam and gripper away from the motor, and the speed sensor and temperature sensor are installed on the motor.

4. The forging stepping beam servo control system according to claim 2, characterized in that, The controller obtains the travel distances of the stepper beam based on the information from the displacement sensor, speed sensor, and temperature sensor, and transmits the signals to the industrial control computer so that the controller can adjust the motor status and the delay interval of the stepper beam transport in a timely manner.

5. A servo control method for forging a walking beam, characterized in that, The forging stepper beam servo control system according to any one of claims 1-4 uses an improved active disturbance rejection control algorithm to adjust the angular velocity and angular displacement of the motor in real time, so as to achieve precise control of the stepper beam's movement speed and starting position.

6. The servo control method for a forging walking beam according to claim 5, characterized in that, The improved active disturbance rejection algorithm, based on the traditional nonlinear active disturbance rejection control algorithm, incorporates a nonlinear tracking differentiator, an extended state observer, and a nonlinear function. Improvements have been made.

7. The servo control method for a forging walking beam according to claim 6, characterized in that, The improved active disturbance rejection algorithm eliminates the nonlinear tracking differentiator to reduce tuning difficulty and enhance dynamic response.

8. The servo control method for a forging walking beam according to claim 6, characterized in that, The improved active disturbance rejection algorithm uses a cascaded extended state observer consisting of a first-level extended state observer and a second-level extended state observer. The cascaded extended state observer estimates and compensates for the total disturbance in the control system, thereby achieving rapid tracking of the total disturbance.

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