Powder thickness precision control mechanism and control method thereof

Abstract

The present application relates to a powder thickness precision control mechanism and its control method. The powder thickness precision control mechanism is composed of a conveying belt, a thickness detection mechanism and a scraper mechanism which are vertically mounted on the conveying belt and are fixed on the two sides of the conveying belt by fixed elements, and a control system. The control method includes: (1) setting the thickness of the powder, driving the servo motor of the first lifting mechanism and the second lifting mechanism, thereby driving the speed reducer, the guide column embedded in the output shaft end of the speed reducer moves, the lower end of the screw moves up and down linearly due to the action of the positioning pin, then drives the whole scraper mechanism to move up and down until the set thickness of the powder is reached; (2) reading the thickness of the powder by the first laser ranging sensor and the second laser ranging sensor at the two ends of the thickness detection mechanism, feeding back to the PLC controller to instruct the scraper mechanism to adjust in real time, realizing stable and precise control.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of ceramic tile production, and particularly relates to a powder thickness precise control mechanism and a control method thereof. BACKGROUND

[0002] In the field of ceramic tile production, powder pressing forming is an important process. In the process of ceramic press distribution, distribution control is very important, but the distribution is affected by many factors. Due to many interference factors, the control accuracy is difficult to be very high. In daily production, the thickness of ceramic tile blanks is adjusted, or the local thickness change of the pressed formed tile blank after the change of the powder humidity, particle size distribution and other factors is responded, when the powder is filled into the mold, uneven distribution may occur, some places are thin, some places are thick, especially at both ends of the mold, the thick places may be 2 to 3 times the normal distribution thickness, or the accumulation phenomenon may occur at the corners. In this regard, the common practice in the industry is to adjust the thickness of the pressed formed tile blank by manually adjusting the distribution thickness according to the performance of the powder. In addition, the thickness of each part of the product after pressing is measured, and the local distribution is adjusted according to the thickness of different parts of the product. However, manual adjustment of the distribution often brings uncertainty in thickness adjustment, and it is difficult for manual operation to adjust in time, so that the production stability is affected, and the product is too thick or too thin. Over time, a large amount of degraded products or even waste products will be produced. At present, there is also a lack of monitoring and constant control of the thickness of the distribution powder in the continuous forming production process of the tile blank, so that the problem of one-sided thick or thin products occurs in actual production. SUMMARY

[0003] In view of the above problems, the purpose of the present application is to provide a powder thickness precise control mechanism to solve the problem of unstable product thickness control caused by manual adjustment of the powder thickness. Another purpose of the present application is to provide a precise control mechanism control method which can continuously monitor the change of the powder thickness and automatically adjust the powder thickness.

[0004] The technical solution of the present application is the powder thickness precise control mechanism, which is characterized in that it is composed of a conveying belt, a thickness detection mechanism and a scraper mechanism respectively vertically straddling above the conveying belt and fixedly arranged on both sides of the conveying belt by fixed elements, and a control system.

[0005] As a preferred embodiment, the thickness detection mechanism is composed of a profile, a pair of L-shaped support plates vertically fixed on both sides of the profile and facing each other, and a pair of laser distance sensors respectively fixed on the side edges of the profile adjacent to the top plates.

[0006] Preferably, the scraper mechanism consists of a profile, a scraper fixed to the side of the profile, a pair of parallel lifting mechanisms that are vertically connected to both ends of the profile by profile fixing plates and fixed to the top of the frame by fixing elements, and a frame fixed to the bottom of the lifting mechanism by fixing plates and fixing elements.

[0007] Preferably, the lifting mechanism comprises a first L-shaped fixed plate and a U-shaped fixed plate vertically connected at the bottom; a speed reducer and a servo motor for driving the speed reducer are vertically fixed on the long plate at the top of the first L-shaped fixed plate; a guide post through which the output shaft of the speed reducer passes; a threaded hole in the middle of the guide post; a screw threaded into the guide post; a cylinder fixed to the inner side of the short plate at the top of the U-shaped fixed plate; a piston rod of the cylinder; a horizontal plate for fixing the speed reducer screw and the cylinder piston rod vertically through the second L-shaped fixed plate by fixing elements; a vertical plate of the second L-shaped fixed plate for connecting to the end of the profile by fixing elements; a third L-shaped fixed plate connected to the short plate of the first L-shaped fixed plate along its outer edge by fixing elements; a strip-shaped mounting groove opened on the vertical plate of the third L-shaped fixed plate parallel to the long plate of the first L-shaped fixed plate; and a proximity switch that is fixed by fixing elements and electrically connected to the control system through the strip-shaped mounting groove.

[0008] Preferably, the U-shaped fixing plate has a guide hole on its longitudinal plate, and the lower end of the screw passes through a positioning pin vertically to position the screw and move linearly along the guide hole of the U-shaped fixing plate. The upper end of the screw is bolted to a third L-shaped profile fixing plate by a nut. The outer surface of the guide post has a keyway for installing a key pin, and the guide post is embedded in the output shaft end of the reducer by the key pin. The bottom of the screw is provided with a zero-position identification photoelectric sensor for identifying and locking the zero position of the screw, and the zero-position identification photoelectric sensor is electrically connected to the control system.

[0009] Preferably, the control system includes a touch screen, a PLC controller, a laser thickness range sensor, a servo driver, and a servo motor. The PLC controller is the control core and is connected to the touch screen, laser range sensor, and servo driver via a network cable for signal transmission. When the servo motor receives a drive signal from the servo driver, it drives the reducer, and the guide post embedded in the output shaft of the reducer moves accordingly. The lower end of the screw moves up and down linearly due to the action of the positioning pin.

[0010] Another technical solution of the present invention is a control method for the powder thickness precision control mechanism, which is characterized by including the following steps:

[0011] (1) Set the thickness of the powder, drive the servo motors of the first lifting mechanism and the second lifting mechanism, thereby driving the reducer. The guide column embedded in the output shaft of the reducer moves accordingly. The lower end of the screw will move up and down linearly due to the action of the positioning pin, and then drive the entire scraper mechanism to move up and down until the set thickness of the powder is reached.

[0012] (2) The thickness of the powder is read by the first laser ranging sensor and the second laser ranging sensor at both ends of the thickness detection mechanism, and the feedback is sent to the PLC controller to instruct the scraper mechanism to adjust in real time, so as to achieve stable and precise control.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0014] (1) This invention reduces the probability of product downgrading due to excessive thickness deviation caused by fluctuations in powder material in the previous process, resulting from manual measurement errors or lack of timeliness. It avoids production instability caused by manual operation and ensures the quality of semi-finished products formed by pressing the preform.

[0015] (2) This invention is easy to operate, highly automated, and reduces the labor intensity of employees. Attached Figure Description

[0016] Figure 1 This is an isometric schematic diagram of the powder thickness precision control mechanism of the present invention;

[0017] Figure 2 This is a schematic diagram of the thickness detection mechanism of the powder thickness precision control mechanism of the present invention;

[0018] Figure 3 This is a bottom view of the thickness detection mechanism of the powder thickness precision control mechanism of the present invention;

[0019] Figure 4 This is an isometric view of the scraper mechanism of the powder thickness precision control mechanism of the present invention;

[0020] Figure 5 yes Figure 4 A magnified view of part I;

[0021] Figure 6 yes Figure 4 A schematic diagram of the lifting mechanism of the thickness detection institution;

[0022] Figure 7 yes Figure 4 Exploded view of the lifting mechanism of the thickness measuring agency;

[0023] Figure 8 yes Figure 4 Exploded view of the lifting mechanism of the thickness measuring agency from one perspective;

[0024] Figure 9 yes Figure 4 An exploded view of the lifting mechanism of the thickness measuring agency from another perspective;

[0025] Figure 10 yes Figure 9 A magnified view of part I;

[0026] Figure 11 yes Figure 4 A schematic diagram of the guide column of the lifting mechanism of the thickness detection device;

[0027] Figure 12 This is a system block diagram of the powder thickness precision control mechanism of the present invention;

[0028] Figure 13 This is a flowchart of the process of the powder thickness precision control mechanism of the present invention.

[0029] Explanation of key component symbols:

[0030] Conveyer belt 1 Thickness detection mechanism 2 Scraper mechanism 3 7-shaped support plate 201 Bolt 202 Aluminum profile 203 Bolt 204 Fixed plate 205 Bolt 206 Laser ranging sensor 207 Fixed plate 208 Bolt 209 Laser ranging sensor 210 Foot stand 301 Lifting mechanism 302 Bolt 303 Aluminum profile 304 Bolt 305 Scraper 306 Bolt 307 Lifting mechanism 308 Foot stand 309 Zero electric eye device 310 Proximity switch 3101 Support 3102 Bolt 3103 Aluminum profile fixed plate 30201 Fixed nut 30202 Air cylinder 30203 Bolt 30204 Fixed plate 30205 Bolt 30206 Screw rod 30207 Speed reducer 30208 Servo motor 30209 Fixed plate 30210 Positioning pin 30211 Guide column 30212 Key pin 30213 Threaded hole 30214 Key groove 30215 Detailed Implementation

[0031] The present invention will now be described in further detail with reference to the accompanying drawings:

[0032] Please see Figure 1 The brick thickness control mechanism of this invention consists of a conveyor belt 1, a thickness detection mechanism 2, and a scraper mechanism 3. To better illustrate the implementation of this invention, the side of the conveyor belt 1 driven by the electric motor is defined as the front, and the other side as the rear. The conveyor belt 1 is used to transport powder from the rear to the front. Please continue reading... Figure 1 The scraper mechanism 3 is installed behind the conveyor belt 1; the thickness detection mechanism 2 is installed in front of the conveyor belt; please refer to [link / reference]. Figure 2 The thickness detection mechanism 2 is fixed above the conveyor belt 1 by bolts 202;

[0033] Please see Figure 2 and Figure 3 The thickness detection mechanism 2 consists of two L7-shaped support plates 201 positioned on either side for support, fixed to the conveyor belt 1 by bolts 202. An aluminum profile 203 is provided on the top of the L7-shaped support plate 201, and the L7-shaped support plate 201 and the aluminum profile 203 are fixed together by screws 204. Please continue reading. Figure 3 The thickness detection mechanism 2 is equipped with a laser rangefinder 207 and a laser rangefinder 210. The laser rangefinder 207 is mounted on a fixed plate 205 and then fixed to one end of the aluminum profile 203 by bolts 206. Similarly, the laser rangefinder 210 is mounted on a fixed plate 208 and then fixed to the other end of the aluminum profile 203 by bolts 209.

[0034] Please see Figure 4 The scraper mechanism 3 is supported by legs 301 and 309 distributed on the left and right sides of the conveyor belt 1; please continue reading Figure 4The lifting mechanism 302 is fixed above the stand 301 by bolts 303; similarly, the lifting mechanism 308 is fixed above the stand 309 by the zero-position photoelectric sensor mechanism 310; an aluminum profile 304 is provided between the lifting mechanism 302 and the lifting mechanism 308, which is fixed by bolts 305, and a scraper 306 is provided in front of the aluminum profile, which is fixed by bolts 307;

[0035] Both lifting mechanisms 302 and 308 are Figure 6 The following explanation, using lifting mechanism 302 as an example, illustrates the symbol relationships between its components:

[0036] Please see Figure 6 and Figure 7 The lifting mechanism 302 is provided with a fixing plate 30205 standing above the bracket 301. A cylinder 30203 is provided above it by bolts 30204. A nut 30202 is connected in series above the cylinder 30203 to fix one end of the aluminum profile mounting plate 30201.

[0037] Please continue reading. Figure 6 The lifting mechanism 302 has a fixed plate above the bracket 301, and a screw hole is provided on the top for fixing the reducer 30208. The reducer 30208 is connected in series with the servo motor 30209 as a drive unit.

[0038] Please see Figure 7 and Figure 8 The output shaft of the reducer 30208 is pierced by the guide post 30212; please refer to [link / reference]. Figure 9 and Figure 10 The guide post 30212 has a threaded hole 30214 in the middle for connecting the screw 30207. The lower end of the screw 30207 is connected to a positioning pin 30211 for positioning the screw 30207 and allowing it to move linearly along the guide hole of the fixing plate 30205. The upper end of the positioning screw 30207 is bolted to the aluminum profile fixing plate 30201 by a nut 30206. The outer surface of the guide post 30212 has a keyway 30215 for installing a key pin 30213. The guide post 30212 is embedded in the output shaft end of the reducer 30208 by the key pin 30213. Please refer to [further details omitted]. Figure 5 and Figure 6 The bottom of the positioning screw 30207 is provided with a zero-position photoelectric sensor mechanism 310, which is used to lock the zero position of the positioning screw 30207; the zero-position photoelectric sensor mechanism 310 is provided with a proximity switch 3101 which is inserted between the brackets 3102 and fixed to the bottom of the lifting mechanism 302 by bolts 3103.

[0039] III. Explain the control method using the control flowchart:

[0040] Please see Figure 12To implement the precise control of this invention, the invention includes a brick thickness precision control system, comprising components such as a touch screen, a PLC, a laser thickness sensor, and a servo driver. The PLC is the control core, and signals are transmitted between it and other components via a network cable. The laser ranging sensors 207 and 210 at both ends of the thickness detection mechanism 2 correspond to... Figure 12 Laser rangefinder 1 and laser rangefinder 2; scraper lifting mechanism 302 servo motor 30209 corresponding to Figure 12 The servo motor 1 corresponds to the lifting mechanism 308. Figure 12 The servo motor 2, lifting mechanism 302, and lifting mechanism 308 are respectively located at both ends of the scraper, controlling the height of the scraper at both ends, thereby controlling the thickness of the powder on both sides. Since the structure and motion principle of lifting mechanism 302 and lifting mechanism 308 are the same, the following explanation uses lifting mechanism 302 as an example. When the servo motor 30209 receives the drive signal from the servo driver 1, it drives the reducer 30208. The guide post 30212 embedded in the output shaft end of the reducer 30208 moves accordingly. The lower end of the screw 30207 will move up and down linearly under the action of the positioning pin 30211.

[0041] Please see Figure 12 and Figure 13 The control loop of this invention is described as follows: An initial height M1 of one end of the scraper is set via a touchscreen and then transmitted to the PLC. The PLC then sends a command to the servo driver 1, which in turn drives the servo motor 1 to control one end of the scraper to the set height. The height N1 of the powder is then read by the laser thickness sensor 1 and transmitted to the PLC. Simultaneously, the PLC compares the set powder thickness M1 with the height N1 read by the laser thickness sensor. If M1 is greater than N1, the PLC sends a command to the servo driver to drive the servo motor, causing the scraper to continue rising until M1 equals N1. Conversely, if M1 is less than N1, the PLC sends a command to the servo driver to drive the motor in the opposite direction, causing the scraper to descend until M1 equals N1. The other end of the scraper follows the same steps.

[0042] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the claims of the present invention.

Claims

1. A powder thickness precision control mechanism, characterized in that, The system comprises a conveyor belt, a thickness detection mechanism and a scraper mechanism that are vertically straddling the conveyor belt and fixed to both sides of the conveyor belt by fixing elements, and a control system. The thickness detection mechanism consists of a profile, a pair of L-shaped support plates with facing top plates that are vertically fixed to both sides of the profile, and a pair of laser rangefinders fixed to the sides of the profile adjacent to the top plates. The scraper mechanism consists of a profile, scrapers fixed to the sides of the profile, a pair of parallel lifting mechanisms that are vertically connected to both ends of the profile by profile fixing plates and fixed to the top of the legs by fixing elements, and legs fixed to the bottom of the lifting mechanisms by fixing plates and fixing elements. The control system includes a touch screen, a PLC controller, a laser thickness range sensor, a servo driver, and a servo motor. The PLC controller is the control core and is connected to the touch screen, laser range sensor, and servo driver via a network cable for signal transmission. When the servo motor receives a drive signal from the servo driver, it drives the reducer, and the guide post embedded in the output shaft of the reducer moves accordingly. The lower end of the screw moves up and down linearly due to the action of the positioning pin. The thickness of the powder is read by the first laser ranging sensor and the second laser ranging sensor at both ends of the thickness detection mechanism, and the feedback is sent to the PLC controller to instruct the scraper mechanism to adjust in real time, so as to achieve stable and precise control. The lifting mechanism consists of a first L-shaped fixed plate and a U-shaped fixed plate vertically connected at the bottom; a speed reducer and a servo motor for driving the speed reducer are vertically fixed on the long plate at the top of the first L-shaped fixed plate; a guide column through which the output shaft of the speed reducer passes; a threaded hole in the middle of the guide column; a screw threaded into the guide column; a cylinder fixed on the inner side of the short plate at the top of the U-shaped fixed plate; a piston rod of the cylinder; a horizontal plate for fixing the speed reducer screw and the cylinder piston rod perpendicularly through the second L-shaped fixed plate by fixing elements; a vertical plate of the second L-shaped fixed plate for connecting to the end of the profile by fixing elements; a third L-shaped fixed plate connected to the short plate of the first L-shaped fixed plate along its outer edge by fixing elements; a strip-shaped mounting groove opened on the vertical plate of the third L-shaped fixed plate parallel to the long plate of the first L-shaped fixed plate; and a proximity switch that is fixed by fixing elements and electrically connected to the control system through the strip-shaped mounting groove. The U-shaped fixing plate has a guide hole on its longitudinal plate. The lower end of the screw passes through a positioning pin vertically to position the screw and allow it to move linearly along the guide hole of the U-shaped fixing plate. The upper end of the screw is bolted to the third L-shaped profile fixing plate by a nut. The outer surface of the guide post has a keyway for installing a key pin. The guide post is embedded in the output shaft end of the reducer by the key pin. The bottom of the screw is provided with a zero-position identification photoelectric sensor for identifying and locking the zero position of the screw. The zero-position identification photoelectric sensor is electrically connected to the control system.

2. A control method for the powder thickness precision control mechanism according to claim 1, characterized in that, Includes the following steps: (1) Set the thickness of the powder, drive the servo motors of the first lifting mechanism and the second lifting mechanism, thereby driving the reducer. The guide column embedded in the output shaft of the reducer moves accordingly. The lower end of the screw will move up and down linearly due to the action of the positioning pin, and then drive the entire scraper mechanism to move up and down until the set thickness of the powder is reached. (2) The thickness of the powder is read by the first laser ranging sensor and the second laser ranging sensor at both ends of the thickness detection mechanism, and the feedback is sent to the PLC controller to instruct the scraper mechanism to adjust in real time, so as to achieve stable and precise control.

3. The control method of the powder thickness precision control mechanism according to claim 2, characterized in that, Step (1) further includes: (1.1) The initial height M1 of one end of the scraper is set through the touch screen and transmitted to the PLC controller. The PLC controller then sends an instruction to the first servo driver, which drives the first servo motor to control one end of the scraper to the set height. (1.2) Similarly, perform the above steps on the other end of the scraper.

4. The control method of the powder thickness precision control mechanism according to claim 2, characterized in that, Step (2) further includes: (2.1) The height N1 of the powder is read by the first laser thickness sensor and fed back to the PLC controller. The PLC controller compares the set thickness M1 of the powder with the height N1 read by the first laser thickness sensor. (2.2) If the thickness M1 of the powder is set to be greater than the height N1 read by the first laser thickness sensor, the PLC controller sends an instruction to the first servo driver to drive the first servo motor to drive the scraper to continue to rise until M1 equals N1. (2.2) Conversely, if the thickness M1 of the powder is set to be less than the height N1 read by the first laser thickness sensor, the PLC controller sends a command to the first servo driver to drive the first servo motor to move in the opposite direction and drive the scraper to lower down until M1 equals N1. (2.3) Similarly, perform the above steps on the other end of the scraper.

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