Master-slave multi-device loose type wire unwinding and winding synchronization device and method

Abstract

The application relates to a master-slave multi-device loose type pay-off winding synchronization device and method. The master-slave multi-device loose type pay-off winding synchronization device is constructed through a master device, a slave device, a displacement sensor, a speed regulator, a communication device and a controller. Whether control needs to be performed is judged by detecting the synchronous displacement of the master device and the slave device, the control amount of the slave device is adjusted, the high-frequency pulse type incremental PID mode is used for synchronization, a positive or negative length value is forcibly added to the slave device to adjust the slave device in order to eliminate the static error, the controller automatically updates the parameters of the slave device, and the purpose of fast convergence of the parameters is achieved through iteration. The application can realize automatic work of the slave device under the condition of no or few human interventions, improve work efficiency and reduce labor intensity. Meanwhile, the controller can monitor the master device to realize real-time display of work progress and real-time monitoring of the running state of the slave device in a large time and space range.

Description

Technical Field

[0001] This invention belongs to the field of master-slave multi-device collaboration technology, and in particular, it is a master-slave multi-device loose-type wire feeding and winding synchronization device and method. Background Technology

[0002] In industrial production and construction, situations involving the synchronous control of multiple master and slave devices are frequently encountered. The pace, rhythm, or working speed of the production or construction process is determined by the master equipment, which may be controlled manually and automatically, or automatically according to certain physical laws. It is generally determined by the characteristics of materials, the working environment, or the equipment itself, and operates in a variable-speed manner. Constrained by the master equipment, the slave equipment supplying materials must also coordinate with its movement speed. The slave equipment's speed is ultimately adjusted by the motor's rotational speed, typically controlled by a frequency converter. From an automatic control perspective, the control method is speed regulation, and the control target is displacement. Since displacement or speed measurements always have errors, if these errors cannot be eliminated by automatic control technology, they will accumulate and exceed a threshold, inevitably affecting production or construction. To eliminate the accumulation of static errors, engineering generally uses natural physical constraints to achieve automatic control. For example, on a production line, the tension or pull of the wire is often used to automatically adjust the speed. If the master equipment moves too fast, the wire will tighten, increasing the tension or pull; conversely, if the slave equipment moves too fast, the wire will loosen, decreasing the tension or pull. By automatically adjusting the output speed of the motor by judging the range of tension or pulling force, stable synchronization between master and slave devices can be achieved.

[0003] However, in many situations where tension or tensile force cannot be reliably measured, such as when the wire itself is stiff (e.g., wire used in thermoplastic molding engineering construction), loosely placed wire, the distance between master and slave equipment is too far, or the wire itself needs to cross a medium, static cumulative error cannot be automatically eliminated. In general, manual intervention is required, and manual adjustment is commonly used. This not only requires additional manpower and has low work efficiency, but also makes coordination between multiple devices and manual personnel very inconvenient.

[0004] To address the problem that when devices are geographically distant and scattered, the only way to control the synchronization of master and slave devices is by using displacement sensors combined with speed regulation, which is highly dependent on manual adjustments and inefficient, it is necessary to design a suitable control method and adopt appropriate equipment. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and propose a master-slave multi-device loosely coupled wire feeding and winding synchronization device and method, which enables the slave device to work automatically with no or little human intervention, thereby improving work efficiency and reducing labor intensity.

[0006] The technical problem solved by this invention is achieved through the following technical solution:

[0007] A master-slave multi-device loosely coupled wire feeding and winding synchronization device includes a master device, slave devices, displacement sensors, speed controllers, communication devices, and a controller. The master device is used to process materials output from multiple slave devices into finished products. The slave devices are used to continuously supply materials to the master device. The displacement sensors and speed controllers are connected to the controller via the communication devices. The displacement sensors are installed on both the master device and the slave devices to detect the displacement of the master device and the slave devices. The speed controller is connected to the slave devices to adjust the speed of the slave devices based on the data calculated by the controller. The controller calculates the control quantity that needs to be adjusted based on the displacement detected by the displacement sensors and sends it to the speed controller for speed adjustment.

[0008] A synchronization method for a master-slave multi-device loosely coupled wire feeding and winding synchronization device includes the following steps:

[0009] Step 1: Obtain the displacement sensor coefficients of the master and slave devices, set the period interval for synchronous data exchange between the master and slave devices, set the minimum and maximum values ​​of the synchronization margin, and calculate the pre-release amount and margin threshold of the synchronization length.

[0010] Step 2: After the periodic interval of data exchange between the master and slave devices, the slave device sends status data to the master device. After receiving the status data from the slave device, the master device immediately sends its current status data to the slave device.

[0011] Step 3: The controller synchronizes the slave device using a high-frequency pulse incremental PID mode based on the status data of the master and slave devices.

[0012] Step 4: The master device determines when the synchronization length difference between the slave device and the master device is about to exceed the minimum threshold value L. min or maximum value L max Input a single intervention signal, and the controller calculates the displacement sensor coefficient of the device based on the intervention signal;

[0013] Step 5: Input the displacement sensor coefficients obtained in Step 4 into Step 2 for looping.

[0014] Furthermore, the specific implementation method of step 1 is as follows: the main device confirms the displacement sensor coefficient K. m Confirm the displacement sensor coefficient K from the equipment. s Set the periodic interval Δt for synchronous data exchange between master and slave devices, and the minimum synchronization margin L. min and maximum value L max And the pre-release amount L and margin threshold ΔL of the synchronization length:

[0015] L=(L max +L min ) / 2

[0016] ΔL=(L max -L min ) / 2

[0017] Furthermore, the proportional-integral-derivative parameter K was determined to be used in a high-frequency pulse-type incremental PID mode. p K i K d .

[0018] Furthermore, the specific implementation method of step 2 is as follows: every Δt time interval, the slave device sends status data to the master device, including the displacement sensor measurement pulse count N. s The synchronous displacement L measured by the device from the start to the current time. s_sync L s_sync =N s ×K s After receiving the status data from the slave device, the master device immediately sends its current status data to the slave device, including the displacement sensor measurement pulse count N. m The displacement L measured by the device from the start to the current moment. m Synchronous displacement L m_sync L m_sync =N m ×K m .

[0019] Furthermore, the specific implementation method of step 3 is as follows: the device uses a high-frequency pulse-type incremental PID mode for synchronization:

[0020]

[0021] Among them, K out The parameter is the control quantity output from the equipment speed controller, ranging from 0 to 1. Δt is the measurement time interval, and n is the sample point sequence: 1, 2, 3...n.

[0022] Furthermore, the specific implementation method of step 4 is as follows: the obtained slave device synchronous displacement L s_sync Subtract the synchronous displacement L of the main equipment m_sync If the difference is within the minimum value of the synchronization margin L min and maximum value L max In the meantime, no mandatory intervention is required; otherwise, the device needs to consider the intervention signal and input a single intervention signal, accumulating or subtracting a quantity ΔL. a This step forces an additional positive or negative length value to be added from the device burst, and the synchronization strategy of the device controller is not affected.

[0023] Based on the intervention amount ΔL from the equipment a The value of the displacement sensor coefficient K is calculated using the synchronization data after each insertion. s:

[0024] K s (n)=K s (n-1)×L m_sync / (L s_sync ±ΔL a )

[0025] Among them, K s (n) represents the displacement sensor coefficient from the nth step of the device, L m_sync It is the total displacement of the master device at the current moment, L s_sync ±ΔL a This represents the total displacement after intervention at the current moment in the equipment.

[0026] The advantages and positive effects of this invention are:

[0027] This invention constructs a master-slave multi-device loosely coupled wire feeding and winding synchronization device using a master device, slave devices, displacement sensors, a speed controller, a communication device, and a controller. It determines the need for control by detecting the synchronous displacement of the master and slave devices, adjusting the control input of the slave device accordingly. High-frequency pulse-type incremental PID mode is used for synchronization. To reduce errors, the slave device is forced to suddenly accumulate an additional positive or negative length value, thus adjusting it. This allows the controller to automatically update the slave device's parameters, achieving rapid parameter convergence through iteration. This invention enables the slave devices to operate automatically with little or no human intervention, improving work efficiency and reducing labor intensity. Simultaneously, the controller can monitor the master device's real-time progress and the slave device's operating status, allowing for real-time monitoring of equipment status over a large time and space range. Attached Figure Description

[0028] Figure 1 This is a structural diagram of the device of the present invention;

[0029] Figure 2 This is an overall flowchart of the present invention;

[0030] Figure 3 This is a flowchart of the main device of the present invention;

[0031] Figure 4 This is a flowchart of the device of the present invention. Detailed Implementation

[0032] The present invention will be further described in detail below with reference to the accompanying drawings.

[0033] A master-slave multi-device loose-type wire feeding and winding synchronization device, such as Figure 1 As shown, it includes a master device, a slave device, a displacement sensor, a speed controller, a communication device, and a controller.

[0034] The main equipment is used to automatically or manually control the working equipment to press, produce, manufacture or install two or more wires, profiles or strips into a finished product, and operates in variable speed mode.

[0035] The device is used for passive control of equipment, providing continuous raw materials such as wires, profiles or strips to the main equipment. The feeding speed is controlled by speed regulation, without physical synchronization of the main equipment's displacement. The wires, profiles, strips, etc. provided are loose, and due to space and environmental limitations and considerations for coordination with the main equipment, the release amount needs to have an extra margin, but there is an upper limit.

[0036] Displacement sensors are used to measure displacement. These include photoelectric encoders, magnetoelectric encoders, laser encoders, or other sensor devices that can directly output displacement.

[0037] The displacement sensor is installed on the winding head of the main equipment: One solution adopted in this invention is that a gear is installed on the encoder shaft, which is connected to the gear on the main shaft of the winding head via a chain. The speed ratio can be calculated based on the gear ratio, and the coefficient K can be derived by combining it with the outer diameter of the pressure roller on the main shaft of the winding head. m K m This indicates the displacement of the pressure pulley on the main shaft of the machine head corresponding to the unit pulse output of the encoder, which is the distance the profile moves. An encoder is installed on the equipment to measure the profile conveying parameters.

[0038] A speed controller is used to set the voltage or current to control the speed of the motor driving the slave device.

[0039] The controller has communication and data processing capabilities. It reads displacement sensor data to obtain displacement values, exchanges equipment status data through the communication unit, controls the frequency converter to achieve speed regulation, and achieves displacement synchronization.

[0040] The displacement sensor and speed controller are connected to the controller via communication devices (such as Ethernet, PROFINET, DP, RS485 or other interface buses). The displacement sensor is installed on the master device and the slave device respectively to detect the displacement of the master device and the slave device. The speed controller is connected to the slave device to adjust the speed of the slave device according to the data calculated by the controller.

[0041] This invention achieves two objectives by injecting intervention signals from the device, adjusting the sensor coefficients of the device, achieving rapid iterative convergence, and eliminating static errors:

[0042] I. Dynamic synchronous tracking is achieved through measurement data, data interaction, and PID synchronization algorithms;

[0043] Second, static errors are eliminated by injecting intervention signals into the slave device, updating the slave device parameters, and rapidly iterating and converging.

[0044] A synchronization method, such as a master-slave multi-device loose-type wire feeding and winding synchronization device, is provided. Figure 2 As shown, it includes the following steps:

[0045] Step 1.1: The main equipment confirms the displacement sensor coefficient K. m Confirm the displacement sensor coefficient K from the equipment. s Set the periodic interval Δt for synchronous data exchange between master and slave devices, and the minimum synchronization margin L. min and maximum value L max And the pre-release amount L and margin threshold ΔL of the synchronization length:

[0046] L=(L max +L min ) / 2

[0047] ΔL=(L max -L min ) / 2

[0048] Furthermore, the proportional-integral-derivative parameter K was determined to be used in a high-frequency pulse-type incremental PID mode. p K i K d .

[0049] Step 1.2: Every Δt, the slave device sends status data to the master device, including the displacement sensor measurement pulse count N. s The synchronous displacement L measured by the device from the start to the current time. s_sync L s_sync =N s ×K s After receiving the status data from the slave device, the master device immediately sends its current status data to the slave device, including the displacement sensor measurement pulse count N. m The synchronous displacement L measured by the main equipment from the start to the current time. m_sync L m_sync =N m ×K m .

[0050] Step 1.3: Synchronize with the device using a high-frequency pulse-type incremental PID mode:

[0051]

[0052] Among them, K out The parameter is the control quantity output from the equipment speed controller, ranging from 0 to 1. Δt is the measurement time interval, and n is the sample point sequence: 1, 2, 3...n.

[0053] Step 1.4: The master device determines when the synchronization length difference between the slave device and the master device is about to exceed the minimum threshold value L. minor maximum value L max Input a single intervention signal, and accumulate or subtract a quantity ΔL. a This step forces the device to burst an additional positive or negative length value, without affecting the synchronization strategy of the device controller.

[0054] Based on the intervention amount ΔL from the equipment a The value is used to calculate the adaptive adjustment calibration coefficient K after each insertion, using synchronized data. s :

[0055] K s (n)=K s (n-1)×L m_sync / (L s_sync ±ΔL a )

[0056] Among them, K s (n) is the calibration coefficient from the nth step of the equipment, L m_sync It is the total displacement of the master device at the current moment, L s_sync ±ΔL a This represents the total displacement of the device after intervention at the current moment, where increasing the disturbance is positive and decreasing the disturbance is negative.

[0057] Step 1.5: The equipment adjusts the motor speed and synchronizes the displacement by controlling the frequency converter. The equipment outputs a control parameter K with a range of 0 to 1. out The circuit module adapted to the frequency converter will be configured according to the application scenario. out Automatically converts the voltage input to 0-Vcc or the current input to 0-Icc to match the frequency converter, and simultaneously obtains K. s (n) is input into step 1.2 and looped.

[0058] like Figure 3 As shown, the master device synchronization process includes the following steps:

[0059] Step 2.1: Initialize the main device's operating parameters, network status, button status, and adjustment values;

[0060] Step 2.2: Determine whether automatic mode is selected. If automatic mode is selected, proceed to step 2.3; otherwise, end.

[0061] Step 2.3: Determine if the set time has been reached. If the set time has been reached, proceed to step 2.4; otherwise, return to step 2.3.

[0062] Step 2.4: Read the status of the master device, poll the network slave devices, send the master device status and read the slave device data, extract the parameters from the slave device data, determine synchronization, and display the status.

[0063] Step 2.5: Poll the networked devices again to determine if the intervention button has been pressed. If it has, accumulate the intervention data, send the intervention data and return to step 2.5; otherwise, return to step 2.2.

[0064] like Figure 4 As shown, the device synchronization process includes the following steps:

[0065] Step 3.1: Initialize the slave device's operating parameters, network status, button status, and adjustment values;

[0066] Step 3.2: Determine whether automatic mode is selected. If automatic mode is selected, proceed to step 3.3; otherwise, end.

[0067] Step 3.3: Read the network data status of the main device, extract the parameters, and the controller uses the automatic synchronization algorithm to synchronize. At the same time, display the synchronization status and error range. The controller controls the speed regulator to adjust the parameters. Repeat this step until the end.

[0068] It should be emphasized that the embodiments described in this invention are illustrative rather than limiting. Therefore, this invention includes, but is not limited to, the embodiments described in the specific implementation. Any other implementations derived by those skilled in the art based on the technical solutions of this invention are also within the scope of protection of this invention.

Claims

1. A synchronization method for a master-slave multi-device loosely coupled pay-off and winding synchronization device, the synchronization method being implemented based on the master-slave multi-device loosely coupled pay-off and winding synchronization device, characterized in that, Includes the following steps: Step 1: Obtain the displacement sensor coefficients of the master and slave devices, set the period interval for synchronous data exchange between the master and slave devices, set the minimum and maximum values ​​of the synchronization margin, and calculate the pre-release amount and margin threshold of the synchronization length. Step 2: After the periodic interval of data exchange between the master and slave devices, the slave device sends status data to the master device. After receiving the status data from the slave device, the master device immediately sends its current status data to the slave device. Step 3: The controller synchronizes the slave device using a high-frequency pulse incremental PID mode based on the status data of the master and slave devices. Step 4: The master device determines when the synchronization length difference between the slave device and the master device is about to exceed the minimum threshold. or maximum value Input a single intervention signal, and the controller calculates the displacement sensor coefficient of the device based on the intervention signal; Step 5: Input the displacement sensor coefficients obtained in Step 4 into Step 2 for looping; The master-slave multi-device loose-type wire feeding and winding synchronization device includes a master device, slave devices, displacement sensors, speed controllers, communication devices, and a controller. The master device is used to process the materials output by multiple slave devices into finished products. The slave devices are used to continuously supply materials to the master device. The displacement sensors and speed controllers are connected to the controller through the communication devices. The displacement sensors are installed on the master device and the slave devices respectively to detect the displacement of the master device and the displacement of the slave devices. The speed controller is connected to the slave devices to adjust the speed of the slave devices according to the data calculated by the controller. The controller is used to calculate the control quantity that needs to be adjusted based on the displacement detected by the displacement sensors and send it to the speed controller for speed adjustment. The main equipment confirms the displacement sensor coefficient. Confirm the displacement sensor coefficient from the equipment. Set the periodic interval for synchronous data exchange between master and slave devices. Minimum of synchronization margin and maximum value And the pre-release amount of the synchronization length. and margin threshold ; ; ; Furthermore, the proportional-integral-derivative parameters of the high-frequency pulse-type incremental PID mode were determined. , , ; Every The time from which the device sends status data to the master device includes displacement sensor measurement pulse counts. The synchronous displacement measured by the device from the start to the current moment. ,in After receiving the status data from the slave device, the master device immediately sends its current status data to the slave device, including the displacement sensor measurement pulse count. The synchronous displacement measured by the device from the start to the current moment. ,in ; The obtained synchronous displacement from the device Subtract the synchronous displacement of the main equipment If the difference is at the minimum value of the synchronization margin and maximum value In the meantime, no mandatory intervention is required; otherwise, the device needs to consider the intervention signal and input a single intervention signal, accumulating or subtracting a quantity. This step forces an additional positive or negative length value to be added from the device burst, and the synchronization strategy of the device controller is not affected. Based on the intervention amount from the equipment The displacement sensor coefficient is calculated using the synchronization data after each insertion. : ; in, From the equipment number The displacement sensor coefficient of the step, It represents the total displacement of the main equipment at the current moment. This represents the total displacement after intervention at the current moment in the equipment.

2. The synchronization method of the master-slave multi-device loose-type wire feeding and winding synchronization device according to claim 1, characterized in that, The specific implementation method of step 3 is as follows: the device uses a high-frequency pulse-type incremental PID mode for synchronization: ; in, The range of the control quantity output from the equipment speed controller is The parameters, .

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