A system and method for automatic speed adjustment of stamping equipment

Abstract

This invention provides a system and method for automatically adjusting the speed of a stamping machine, comprising: a microcontroller unit for controlling the machine speed and receiving signals from an angle encoder; an angle encoder for acquiring position information of moving parts of the machine and feeding it back to the microcontroller unit; a human-machine interface for displaying speed, angle position, angle encoder resolution and type, accepting user commands, and providing the user with the function of setting a target speed; the microcontroller unit further includes: a signal processing module for filtering the signals fed back from the angle encoder; and a speed self-adjustment algorithm module for automatically adjusting the machine speed to a set value based on the speed data fed back from the angle encoder. The technical solution proposed in this invention significantly improves the automation level and accuracy of speed control in stamping equipment, reduces debugging time and labor costs, while ensuring the stability and consistency of machine speed, thereby improving overall production efficiency and product quality.

Description

Technical Field

[0001] This invention relates to the field of mechanical control technology, and specifically to a system and method for automatically adjusting the speed of a stamping equipment. Background Technology

[0002] With the development of society, the demand for intelligent and automated stamping equipment is increasing. The traditional speed control method of stamping equipment usually relies on an external knob to set a certain speed ratio. This method requires the operator to manually adjust the knob and repeatedly adjust it according to the actual feedback speed of the equipment in order to achieve the desired speed setting value.

[0003] The shortcomings of existing technology: 1. Debugging time: Traditional speed control methods require operators to manually adjust the knob multiple times, observe the actual operating speed of the equipment, and make further adjustments based on feedback. This process is very time-consuming.

[0004] 2. Limited accuracy: Due to the limitations of manual adjustment, it is difficult to achieve very precise speed control, which will affect product quality and production efficiency.

[0005] 3. Low level of automation: Existing stamping equipment has a low level of automation in speed control, and cannot quickly and accurately adjust to the set speed.

[0006] Therefore, existing technologies have shortcomings and need further improvement. Summary of the Invention

[0007] To address the problems existing in the prior art, the present invention provides a system and method for automatically adjusting the speed of stamping equipment.

[0008] To achieve the above objectives, the specific solution of the present invention is as follows: This invention provides a system for automatically adjusting the speed of a stamping equipment, the system comprising: The microcontroller unit (MCU) is used to control the speed of the device and receive signals from the angle encoder; An angle encoder is used to collect position information of moving parts of the equipment and feed it back to the microcontroller unit; The human-computer interaction interface is used to display speed, angle position, angle encoder resolution and type, accept user commands, and provide users with the function of setting target speed.

[0009] Furthermore, the microcontroller unit also includes: The signal processing module is used to filter the signal fed back by the angle encoder. The speed self-adjustment algorithm module is used to automatically adjust the device speed to the set value based on the speed data fed back by the angle encoder.

[0010] Furthermore, the angle encoder sends signals to the microcontroller unit via pulse frequency or industrial communication protocols, including MODBUS protocol, SSI communication protocol, and etherCAT bus protocol.

[0011] Furthermore, the microcontroller unit also has a built-in machine learning model for analyzing the device's operating data and dynamically adjusting the parameters in the speed adjustment algorithm to adapt to the device's characteristics that gradually change over time.

[0012] Furthermore, the microcontroller unit adjusts the speed of the device by controlling the voltage, controlling the current, and using industrial communication protocols.

[0013] The present invention also provides a method for automatically adjusting the speed of a stamping equipment. Based on the above-mentioned automatic adjustment system, the method includes the following steps: S1 collects the position information of the moving parts of the equipment through the angle encoder and feeds it back to the microcontroller unit (MCU); S2, the microcontroller unit receives the signal from the angle encoder and performs filtering processing through the signal processing module; S3 calculates the current speed of the device based on the processed signal; S4, the user sets the target speed and starts the calibration mode through the human-computer interaction interface; S5, after receiving the calibration command, the microcontroller unit automatically controls the equipment to perform the calibration process until the set speed and the feedback speed are consistent; S6, During the calibration process, the microcontroller unit calculates the speed by feeding back the encoder angle change and the change time, and automatically adjusts the speed according to the calculation results to maintain the consistency between the set speed and the feedback speed. S7, when a difference is detected between the set speed and the actual feedback speed, the microcontroller unit automatically adjusts the scaling factor to maintain speed consistency; S8, the microcontroller unit records the potential values ​​at different speeds during the calibration process, and uses these values ​​to determine the consistency relationship between the set speed and the feedback speed, so as to achieve more stable control; S9, after calibration is completed, the microcontroller unit automatically exits the calibration mode and dynamically adjusts the scaling factor during equipment operation to cope with speed changes caused by equipment aging and wear.

[0014] Furthermore, step S7 specifically includes: S71, the microcontroller unit first controls the device to run at a low speed; after the speed stabilizes, the microcontroller unit saves the current speed value and the potential value corresponding to the set speed controlled by the microcontroller unit; then it accelerates, and after the speed stabilizes, the microcontroller unit saves the current speed value and the potential value corresponding to the set speed controlled by the microcontroller unit; based on the relationship y=ax+b that a straight line can be determined between two points, the ratio a and the factor b of the potential value corresponding to the set speed and the feedback speed are calculated; where y is the speed, a is the potential value corresponding to the set speed; the potential value of the set speed is the value that controls the motor speed. The speed obtained by controlling different potential values ​​will be different depending on the resolution. When the resolution is 4096 and the potential value of the set speed is 4096, the motor runs at the maximum speed, which is determined according to the maximum speed of the motor specifications; S72, according to step S71, obtain the potential value relationship between multiple point feedback speeds and the set speed; adopt a multi-point calibration method to achieve a more stable speed; S73, after calibration, the ratio will not change, but the factor will automatically adjust and dynamically change as the equipment wears down and frictional resistance becomes inconsistent, causing the speed to be unstable, so as to achieve consistency between the set speed and the feedback speed.

[0015] Furthermore, in step S9, the microcontroller unit predicts future wear based on the device's historical operating data and pre-adjusts the scaling factor to compensate for the expected wear effect, thereby correcting the speed deviation in advance.

[0016] Furthermore, in step S9, the microcontroller unit automatically adjusts the scaling factor according to changes in ambient temperature to compensate for speed deviations caused by temperature changes, ensuring the stability of the equipment under different temperature conditions.

[0017] Furthermore, the method also includes step S10, where the microcontroller unit monitors the operating status of the device. When an abnormal situation is detected, including encoder signal loss or speed fluctuations exceeding the preset range, a safety mechanism is automatically triggered to reduce the device speed to a safety threshold or stop the device from operating. At the same time, the user is prompted to perform inspection and maintenance through the human-machine interface.

[0018] The technical solution of this invention has the following beneficial effects: 1. Improve debugging efficiency: By automatically adjusting the speed, the time spent on manual debugging is reduced, thus improving debugging efficiency.

[0019] 2. Ensure stable speed: The automatic speed adjustment method is used to ensure the stability of the equipment speed and avoid speed fluctuations caused by manual adjustment.

[0020] 3. Improved accuracy: Through the MCU and speed self-adjustment algorithm, more precise control of equipment speed is achieved, improving product quality and production efficiency.

[0021] 4. Intelligent calibration mode: Users can start the calibration mode through the human-computer interaction interface, which will automatically adjust the device speed to ensure that the set speed is consistent with the actual feedback speed.

[0022] 5. Dynamic adjustment capability: Even if mechanical wear or resistance changes occur after long-term operation of the equipment, the MCU can maintain the consistency between the set speed and the feedback speed by automatically adjusting the proportional factor. Attached Figure Description

[0023] Figure 1 This is a system principle block diagram of the present invention; Figure 2 This is an overall flowchart of the present invention; Figure 3 This is a detailed process diagram of step S7 of the present invention. Detailed Implementation

[0024] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention. It should also be noted that, for ease of description, only the parts related to the present invention are shown in the accompanying drawings, and not all of them.

[0025] Combination Figures 1-3 As shown, the present invention provides a system for automatically adjusting the speed of a stamping equipment, the system comprising: The microcontroller unit (MCU) is used to control the speed of the device and receive signals from the angle encoder; An angle encoder is used to collect position information of moving parts of the equipment and feed it back to the microcontroller unit; The human-computer interaction interface is used to display speed, angle position, angle encoder resolution and type, accept user commands, and provide users with the function of setting target speed.

[0026] Microcontroller Unit (MCU): Main function: As the "brain" of the entire system, it is responsible for processing all input data and controlling the speed of the stamping equipment according to preset programs or user instructions.

[0027] Control output: Adjust the motor speed based on the collected data (such as the difference between the current speed and the set speed of the equipment) to achieve precise control of the equipment speed.

[0028] Signal reception: Receives signals from the angle encoder to monitor the actual position of the moving parts of the equipment and ensure the accurate execution of control commands.

[0029] Angle encoder: It monitors the position changes of key moving parts of the equipment (such as drive shafts) in real time by being installed on them.

[0030] Signal transmission: Convert position information into electrical signals and send them to the MCU for processing.

[0031] The encoder can be either absolute or incremental. An absolute encoder can directly provide the current position information, while an incremental encoder records the amount of position change and requires a reference point to determine the actual position.

[0032] The human-machine interface (HMI) displays important parameters such as the current speed and angle position of the equipment, helping operators monitor the equipment status.

[0033] User input: Allows users to input commands, such as setting a target speed or adjusting device parameters.

[0034] Configuration options: Provides options to set the angle encoder resolution and type, so that adjustments can be made according to specific application requirements.

[0035] The microcontroller unit also includes: The signal processing module is used to filter the signal fed back by the angle encoder. The speed self-adjustment algorithm module is used to automatically adjust the device speed to the set value based on the speed data fed back by the angle encoder.

[0036] The signal processing module preprocesses the signal fed back by the angle encoder, especially by filtering it to eliminate noise interference and ensure the accuracy of the data in subsequent processing.

[0037] The signal processing module uses digital filters (such as low-pass filters) to smooth the signal and reduce the impact of high-frequency noise. This helps improve the accuracy and stability of angular position measurements.

[0038] The speed self-adjustment algorithm module uses speed data fed back from the angle encoder to dynamically adjust the device speed through a built-in algorithm, making it as close as possible to the target speed set by the user.

[0039] This algorithm is based on the closed-loop control principle, including proportional-integral-derivative (PID) control or other advanced control strategies such as fuzzy logic control or adaptive control. The PID controller can adjust the control signal according to the error (i.e., the difference between the set speed and the actual speed), so that the equipment speed can be quickly stabilized near the target value.

[0040] When the equipment load changes or external conditions change, the speed self-adjustment algorithm module can respond in a timely manner to maintain the stability and efficiency of equipment operation.

[0041] The angle encoder sends signals to the microcontroller unit via pulse frequency or industrial communication protocols, including MODBUS, SSI, and etherCAT bus protocols.

[0042] Pulse frequency communication: This method uses output pulse frequencies to represent the position information of moving parts of a device. Typically, each pulse represents a certain angular displacement or distance.

[0043] The microcontroller unit also has a built-in machine learning model for analyzing the device's operating data and dynamically adjusting the parameters in the speed adjustment algorithm to adapt to the device's characteristics that change over time.

[0044] Machine learning models: By collecting and analyzing large amounts of data during equipment operation, machine learning models can identify the equipment's behavior patterns over time and its optimal operating parameters under different conditions. Machine learning models can acquire data from angle encoders and other sensors, such as the equipment's speed, load, and temperature. The model preprocesses this data, including cleaning and normalization steps, to ensure data quality and consistency.

[0045] Dynamic parameter adjustment: As equipment is used over time, its characteristics may change due to wear, aging, and other factors. Machine learning models can continuously monitor the equipment's status, identify these changes, and adjust the parameters in the speed adjustment algorithm accordingly to ensure optimal equipment performance.

[0046] When equipment begins to show slight wear, a machine learning model may detect that the time required for the equipment to reach a set speed is increasing, or that the equipment is vibrating more at a specific speed. In this case, the model will adjust the proportional, integral, and derivative parameters of the PID controller accordingly to optimize the equipment's speed control.

[0047] The microcontroller unit adjusts the speed of the device by controlling voltage, controlling current, and using industrial communication protocols.

[0048] The present invention also provides a method for automatically adjusting the speed of a stamping equipment. Based on the above-mentioned automatic adjustment system, the method includes the following steps: S1 collects the position information of the moving parts of the equipment through the angle encoder and feeds it back to the microcontroller unit (MCU); S2, the microcontroller unit receives the signal from the angle encoder and performs filtering processing through the signal processing module; S3 calculates the current speed of the device based on the processed signal; S4, the user sets the target speed and starts the calibration mode through the human-computer interaction interface; S5, after receiving the calibration command, the microcontroller unit automatically controls the equipment to perform the calibration process until the set speed and the feedback speed are consistent; S6, During the calibration process, the microcontroller unit calculates the speed by feeding back the encoder angle change and the change time, and automatically adjusts the speed according to the calculation results to maintain the consistency between the set speed and the feedback speed. S7, when a difference is detected between the set speed and the actual feedback speed, the microcontroller unit automatically adjusts the scaling factor to maintain speed consistency; S8, the microcontroller unit records the potential values ​​at different speeds during the calibration process, and uses these values ​​to determine the consistency relationship between the set speed and the feedback speed, so as to achieve more stable control; S9, after calibration is completed, the microcontroller unit automatically exits the calibration mode and dynamically adjusts the scaling factor during equipment operation to cope with speed changes caused by equipment aging and wear.

[0049] Step S7 specifically includes: S71, the microcontroller unit first controls the device to run at a low speed; after the speed stabilizes, the microcontroller unit saves the current speed value and the potential value corresponding to the set speed controlled by the microcontroller unit; then it accelerates, and after the speed stabilizes, the microcontroller unit saves the current speed value and the potential value corresponding to the set speed controlled by the microcontroller unit; based on the relationship y=ax+b that a straight line can be determined between two points, the ratio a and the factor b of the potential value corresponding to the set speed and the feedback speed are calculated; where y is the speed, a is the potential value corresponding to the set speed; the potential value of the set speed is the value that controls the motor speed. The speed obtained by controlling different potential values ​​will be different depending on the resolution. When the resolution is 4096 and the potential value of the set speed is 4096, the motor runs at the maximum speed, which is determined according to the maximum speed of the motor specifications; S72, according to step S71, obtain the potential value relationship between multiple point feedback speeds and the set speed; adopt a multi-point calibration method to achieve a more stable speed; S73, after calibration, the ratio will not change, but the factor will automatically adjust and dynamically change as the equipment wears down and frictional resistance becomes inconsistent, causing the speed to be unstable, so as to achieve consistency between the set speed and the feedback speed.

[0050] In step S9, the microcontroller unit predicts future wear based on the device's historical operating data and pre-adjusts the scaling factor to compensate for the expected wear effect, thereby correcting the speed deviation in advance.

[0051] The microcontroller unit automatically adjusts the scaling factor based on changes in ambient temperature to compensate for speed deviations caused by temperature variations, ensuring the stability of the equipment under different temperature conditions.

[0052] The method also includes step S10, where the microcontroller unit monitors the operating status of the device. When an abnormal situation is detected, including encoder signal loss or speed fluctuations exceeding the preset range, a safety mechanism is automatically triggered to reduce the device speed to a safety threshold or stop the device from operating. At the same time, the user is prompted to perform inspection and maintenance through the human-machine interface.

[0053] Working principle: This invention relates to a system and method for automatically adjusting the speed of a stamping equipment, the working principle of which mainly includes the following aspects: Angle encoders acquire position information: An angle encoder is installed on the moving parts of the stamping equipment to acquire the position information of the parts and feed this information back to the microcontroller unit (MCU).

[0054] MCU Control and Processing: The MCU is responsible for receiving feedback signals from the angle encoder and processing them, including signal filtering and data parsing. In addition, the MCU is also used to control the speed of the stamping equipment.

[0055] Human-computer interaction interface: The human-computer interaction interface is used to display information such as the device's speed and angle position, and allows users to set the target speed and start the calibration mode.

[0056] Speed ​​self-adjustment algorithm: This algorithm automatically adjusts the device speed to the set value based on the speed data fed back by the angle encoder, ensuring that the set speed is consistent with the actual feedback speed.

[0057] Signal acquisition and processing: The MCU acquires signals from the angle encoder, performs signal filtering, and processes the acquired signals. The signal acquisition method can be pulse frequency or mainstream industrial communication protocols (such as MODBUS protocol, SSI communication protocol, etherCAT bus protocol, etc.).

[0058] Angle value calculation and display: The MCU calculates the angle value by collecting the signal from the angle encoder and transmits these values ​​to the human-machine interface for display.

[0059] Automatic calibration mode: The user sets the target speed and initiates calibration mode through the human-machine interface. After receiving the calibration command, the MCU automatically controls the equipment to perform the calibration process until the set speed and the feedback speed are consistent.

[0060] Dynamic adjustment of scaling factor: Even if mechanical parts age or wear after the equipment has been running for a long time, causing a difference between the set speed and the actual feedback speed, the MCU will automatically adjust the scaling factor to dynamically adjust the equipment speed in real time, ensuring that the set speed and the feedback speed are consistent.

[0061] Methods of controlling equipment speed: The methods of controlling equipment speed can vary depending on the different motion control drivers used in the equipment. For example, control voltage, control current, or use mainstream industrial communication methods (such as MODBUS protocol, SSI communication protocol, etherCAT bus protocol, etc.).

[0062] In summary, this invention, by combining an angle encoder, MCU, human-machine interface, and speed self-adjustment algorithm, realizes automatic speed adjustment of stamping equipment, improves the accuracy and automation level of speed control, and reduces debugging time and labor costs.

[0063] The above description is only a preferred embodiment of the present invention and does not limit the scope of the invention. All equivalent structural transformations made under the inventive concept of the present invention using the description and drawings of the present invention, or direct / indirect applications in other related technical fields, are included within the protection scope of the present invention.

Claims

1. A method for automatically adjusting the speed of a stamping equipment, characterized in that, The method includes the following steps: S1, the position information of the moving parts of the device is collected by the angle encoder and fed back to the microcontroller unit; S2, the microcontroller unit receives the signal from the angle encoder and performs filtering processing through the signal processing module; S3 calculates the current speed of the device based on the processed signal; S4, the user sets the target speed and starts the calibration mode through the human-computer interaction interface; S5, after receiving the calibration command, the microcontroller unit automatically controls the equipment to perform the calibration process until the set speed and the feedback speed are consistent; S6, During the calibration process, the microcontroller unit calculates the speed by feeding back the encoder angle change and the change time, and automatically adjusts the speed according to the calculation results to maintain the consistency between the set speed and the feedback speed. S7, when a difference is detected between the set speed and the actual feedback speed, the microcontroller unit automatically adjusts the scaling factor to maintain speed consistency; S8, the microcontroller unit records the potential values ​​at different speeds during the calibration process, and uses these values ​​to determine the consistency relationship between the set speed and the feedback speed, so as to achieve more stable control; S9, after calibration is completed, the microcontroller unit automatically exits the calibration mode and dynamically adjusts the scaling factor during equipment operation to cope with speed changes caused by equipment aging and wear. Step S7 specifically includes: S71, the microcontroller unit first controls the device to run at a low speed; after the speed stabilizes, the microcontroller unit saves the current speed value and the potential value corresponding to the set speed controlled by the microcontroller unit; then it accelerates, and after the speed stabilizes, the microcontroller unit saves the current speed value and the potential value corresponding to the set speed controlled by the microcontroller unit; based on the relationship y=ax+b that a straight line can be determined between two points, the ratio a and the factor b of the potential value corresponding to the set speed and the feedback speed are calculated; where y is the speed, a is the potential value corresponding to the set speed; the potential value of the set speed is the value that controls the motor speed. The speed obtained by controlling different potential values ​​will be different depending on the resolution. When the resolution is 4096 and the potential value of the set speed is 4096, the motor runs at the maximum speed, which is determined according to the maximum speed of the motor specifications; S72, according to step S71, obtain the potential value relationship between multiple point feedback speeds and the set speed; adopt a multi-point calibration method to achieve a more stable speed; S73, after calibration, the ratio will not change, but the factor will automatically adjust and dynamically change as the equipment wears down and frictional resistance becomes inconsistent, causing the speed to be unstable, so as to achieve consistency between the set speed and the feedback speed.

2. The method according to claim 1, characterized in that, In step S9, the microcontroller unit predicts future wear based on the device's historical operating data and pre-adjusts factors to compensate for the expected wear effect, thereby correcting speed deviations in advance.

3. The method according to claim 1, characterized in that, In step S9, the microcontroller unit automatically adjusts the factor according to the change in ambient temperature to compensate for the speed deviation caused by the temperature change and ensure the stability of the equipment under different temperature conditions.

4. The method according to claim 1, characterized in that, The method also includes step S10, where the microcontroller unit monitors the operating status of the device. When an abnormal situation is detected, including encoder signal loss or speed fluctuations exceeding the preset range, a safety mechanism is automatically triggered to reduce the device speed to a safety threshold or stop the device from operating. At the same time, the user is prompted to perform inspection and maintenance through the human-machine interface.

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