An automatic control system for a wall panel forming machine

Abstract

The present invention discloses an automatic control system for a wall panel forming machine, which relates to the field of automatic control technology, including a working end layout unit, an actual control drill unit, a control end actual control feedback unit, a central control real-time processing unit, an actual control adjustment unit, a period adjustment unit and a manual adjustment unit. The working end layout unit places data acquisition sensors at each working end inside the forming machine, and the forming extrusion end uses a micro pressure controller to monitor the extrusion end. In the process of automatic control of the forming machine, the present invention can not only monitor the working end in real time, and then analyze and adjust the working end, but also monitor the control end and automatically control the control end. In the process of automatic control, the adjustment can be more comprehensive and quick, avoiding the situation that only the working end or only the control end can be adjusted and controlled during the adjustment and control process, which will reduce the accuracy in the specific control process and increase the limitations in the use process.

Description

Technical Field

[0001] The present invention relates to the field of automatic control technology, in particular to an automatic control system for a wall panel forming machine. Background Art

[0002] At present, the wall panel forming machine refers to the method of using vertical mold template cavity forming, flat mold template forming, and extrusion forming to make wall panels;

[0003] During the processing of the existing forming machine, a control system is required to control the forming machine. However, during the operation, the existing control system cannot provide accurate feedback and control according to the situation when the plate is pressed. At the same time, during the automatic control process, it cannot perform real-time monitoring and adjustment with the control end, and can only perform real-time monitoring and adjustment on the working end. This will have great limitations and reduce the limitations and accuracy of the real-time monitoring process of the working end. Summary of the Invention

[0004] The object of the present invention is to provide an automatic control system for a wall panel forming machine to solve the problems raised in the above background technology.

[0005] To achieve the above-mentioned object, the present invention provides the following technical solution: an automatic control system for a wall panel forming machine, comprising a working end layout unit, a real control rehearsal unit, a control end real control feedback unit, a central control real-time processing unit, a real control adjustment unit, a period adjustment unit, and a manual adjustment unit:

[0006] The working end layout unit places data acquisition sensors at each working end inside the molding machine, and the molding extrusion end uses a micro pressure controller to monitor the extrusion end, and separately classifies and collects the collected data;

[0007] The actual control rehearsal unit receives the data transmitted by the working end layout unit and constructs a virtual molding machine through 3D modeling technology. A virtual acquisition sensor is also placed on the virtual molding machine, and the virtual control end and the working end are marked corresponding to the real situation.

[0008] The actual control feedback unit of the control end receives the data transmitted by the actual control rehearsal unit, and compares the monitoring results of each working end and the implementation end according to the results of the implementation rehearsal. When the monitoring end is in use, the data generated by the simulation rehearsal in the rehearsal simulation unit is used as a data reference when making the final judgment. The actual control feedback unit of the control end can also monitor the tiny devices and control end inside the molding machine in real time, and set up a database for abnormal processing of the control end inside the control end, and classify the abnormal problems of the control end into the first, second and third levels respectively, and formulate the first processing plan, the second processing plan and the third processing plan respectively;

[0009] The central control real-time processing unit receives the data transmitted by the control end real-time feedback unit, integrates the information again when receiving the feedback information, and collects the material data of the plate during each pressing process;

[0010] The implementation adjustment unit receives the data transmitted by the central control real-time processing unit. After the data reception is completed, the working end and the control end of the molding machine are directly adjusted and controlled. When the adjustment control is performed, the state data of the direct adjustment is saved and judged by the judgment formula, which is as follows:

[0011]

[0012] Among them, ΔU k is the error threshold, k p is the error change rate, k is the acquisition point, e k is the difference of the acquisition point, k d is the reference parameter value, t is the t-th cycle of acquisition;

[0013] The period adjustment unit receives the data transmitted by the central control real-time processing unit, and records the number of adjustments each time the data is received and adjusted.

[0014] Preferably, the working end layout unit classifies and processes the collected data, and labels the outside of each sensor, wherein the working end sensors are labeled in English letters, and the working end is labeled in Arabic numerals, and the collection sensors placed on the control end are uniformly classified into the control database, and the data collected by the working end are uniformly classified into the working end database, and after the control database and the working end database are established, they are reviewed and improved by experts;

[0015] The period adjustment unit is set with the number of adjustments, and is set to once every twenty days, twice every ten days, and three times every five days, and corresponding warning alarms are formulated, which are set to the first alarm, the second alarm, and the third alarm, respectively. The third alarm has the highest severity, and the first alarm has the lowest severity.

[0016] Preferably, after the virtual molding machine modeling is completed, the actual control rehearsal unit formulates the first simulation plan, the second simulation plan and the third simulation plan respectively, and simulates and rehearses the formulated plans in turn, collects the problems generated in the process of simulation rehearsal, and analyzes and processes the problem data in the collection process. After the analysis and processing is completed, the first treatment plan, the second treatment plan and the third treatment plan are formulated respectively corresponding to the first simulation plan, the second simulation plan and the third simulation plan, and the first simulation plan, the second simulation plan and the third simulation plan are re-simulated every half a month, and the first treatment plan, the second treatment plan and the third treatment plan are re-formulated every twenty days, and in the process of simulation formulation, reference is made to the problems generated in actual work.

[0017] Preferably, the control end actual control feedback unit includes a micro-monitoring module and an implementation end monitoring module. The micro-monitoring module monitors the small devices in the molding machine, and classifies the monitored objects during the monitoring process into commonly used and infrequently used ones. Commonly used small devices are monitored in real time, and infrequently used ones are monitored and fed back once every thirty seconds. If no abnormality occurs for twelve consecutive hours, it will automatically change to one-minute monitoring and feedback. When no abnormality occurs for twenty-four hours, it will automatically change to one-minute and thirty-second monitoring and feedback. Similarly, if an abnormality occurs in any of the above time periods, it will be uniformly corrected to twenty-second monitoring and feedback. If no abnormality occurs within twenty seconds after the correction, it will be corrected to thirty seconds monitoring and feedback.

[0018] Preferably, the implementation end monitoring module monitors the processing extrusion end of the molding machine in real time, and sets the pressure value that produces abnormalities during processing, and sets them to level one, level two and level three respectively, among which the pressure value set at level one is the largest, and the pressure value set at level three is the smallest. After the pressure value is set, before each processing, the specific pressure values ​​of levels one, two and three are adjusted according to the pressure requirements of the specific processing. When the error generated during processing reaches level one, feedback will be directly given to stop working. When it reaches level two and level three, fine-tuning will be automatically performed to keep the positions of each pressure end consistent, thereby ensuring stability during processing.

[0019] Preferably, the central control real-time processing unit includes a material judgment module and a multi-judgment module. Before processing, the material judgment module sets the models of plates of different materials in advance and marks them according to the hardness of the materials. The marking uses a combination of uppercase English letters and Arabic numerals, and the larger the Arabic numerals, the greater the hardness of the material, and the pressure value is adjusted according to different materials.

[0020] Preferably, the multiple judgment modules set the thickness of the plate to be processed and extruded in advance, and the thickness is set to two centimeters, four centimeters and six centimeters respectively, and a custom adjustment library is set, and the custom adjustment library is adjusted according to the specific needs of use, and adjusted to millimeters. At the same time, the size of the plate during processing is limited, and marked by A, B and C respectively, where A represents the largest size and C represents the smallest size, and a custom setting library is also set to adjust according to the area of ​​specific needs.

[0021] Preferably, when the actual control adjustment unit is unable to adjust the working end and the control end, the manual adjustment unit communicates and warns with external experts and experienced employees, and then allows the experts and experienced employees to make adjustments as soon as possible, and the adjustment operation is divided into online adjustment operation and offline adjustment operation, among which the expert adjustment adopts online remote operation and online remote guidance adjustment, while the experienced employee adjustment adopts offline adjustment, and one experienced employee can be responsible for two molding machines.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] During the process of automatic control of the molding machine, the present invention can not only monitor the working end in real time and then analyze and adjust the working end, but also monitor the control end and perform automatic control feedback on the control end. In addition, during the automatic control process, the adjustment can be more comprehensive and quick, avoiding the situation where only the working end or only the control end can be adjusted and controlled during the adjustment and control process, which will reduce the accuracy in the specific control process and increase the limitations during use. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A system flow diagram is provided for an embodiment of the present invention. DETAILED DESCRIPTION

[0025] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0026] See also Figure 1 The present invention provides a technical solution: an automatic control system for a wall panel forming machine, comprising a working end layout unit, a real control rehearsal unit, a control end real control feedback unit, a central control real-time processing unit, a real control adjustment unit, a period adjustment unit, and a manual adjustment unit:

[0027] The working end layout unit places data acquisition sensors at each working end inside the molding machine. The molding extrusion end uses a micro pressure controller to monitor the extrusion end and separately classify and collect the collected data;

[0028] The actual control rehearsal unit receives the data transmitted by the work end layout unit and builds a virtual molding machine through 3D modeling technology. Virtual acquisition sensors are also placed on the virtual molding machine, and the virtual control end and the work end are marked with corresponding real situations.

[0029] The actual control feedback unit at the control end receives the data transmitted by the actual control rehearsal unit, and compares the monitoring results of each working end and the implementation end according to the results of the implementation rehearsal. When the monitoring end is in use, the data generated by the simulation rehearsal in the rehearsal simulation unit is used as a reference when making the final judgment. The actual control feedback unit at the control end can also monitor the tiny devices and control end inside the molding machine in real time, and set up a database for abnormal processing of the control end inside the control end, and classify the abnormal problems of the control end into the first, second and third levels respectively, and formulate the first processing plan, the second processing plan and the third processing plan respectively;

[0030] The central control real-time processing unit receives the data transmitted by the real-time feedback unit of the control end, integrates the information again after receiving the feedback information, and collects the material data of the plate during each pressing process;

[0031] The implementation adjustment unit receives the data transmitted by the central control real-time processing unit. After the data reception is completed, the working end and the control end of the molding machine are directly adjusted and controlled. When the adjustment control is performed, the state data of the direct adjustment is saved and judged by the judgment formula, which is as follows:

[0032]

[0033] Among them, ΔU k is the error threshold, k p is the error change rate, k is the acquisition point, e k is the difference of the acquisition point, k d is the reference parameter value, t is the t-th cycle of acquisition;

[0034] The cycle adjustment unit receives the data transmitted by the central control real-time processing unit, and records the number of adjustments each time the data is received and adjusted.

[0035] The working end layout unit classifies and processes the collected data and labels the external part of each sensor. The working end sensors are labeled with English letters, and the working end is labeled with Arabic numerals. The collection sensors installed at the control end are uniformly classified into the control database, and the data collected by the working end is uniformly classified into the working end database. After the control database and the working end database are established, they are reviewed and improved by experts.

[0036] The periodic adjustment unit is set with the number of adjustments, and is set to once every twenty days, twice every ten days, and three times every five days, and corresponding warning alarms are formulated, which are set to the first alarm, the second alarm, and the third alarm, respectively. The third alarm has the highest severity, and the first alarm has the lowest severity.

[0037] After the virtual molding machine modeling is completed, the actual control rehearsal unit formulates the first simulation plan, the second simulation plan and the third simulation plan respectively, and simulates and rehearses the formulated plans in turn. During the simulation rehearsal, the problems generated are collected, and the problem data are analyzed and processed during the collection process. After the analysis and processing is completed, the first treatment plan, the second treatment plan and the third treatment plan are formulated respectively corresponding to the first simulation plan, the second simulation plan and the third simulation plan, and the first simulation plan, the second simulation plan and the third simulation plan are re-simulated every half a month, and the first treatment plan, the second treatment plan and the third treatment plan are re-formulated every twenty days. In the process of simulation formulation, reference is made to the problems generated in actual work.

[0038] The actual control feedback unit at the control end includes a micro-monitoring module and an implementation end monitoring module. The micro-monitoring module monitors the small devices in the molding machine, and classifies the monitored objects during the monitoring process into commonly used and infrequently used ones. Commonly used small devices are monitored in real time, and infrequently used ones are monitored and fed back once every thirty seconds. If no abnormality occurs for twelve consecutive hours, it will automatically change to one-minute monitoring and feedback. When no abnormality occurs for twenty-four hours, it will automatically change to one-minute and thirty-second monitoring and feedback. Similarly, if an abnormality occurs in any of the above time periods, it will be uniformly corrected to twenty-second monitoring and feedback. If no abnormality occurs within twenty seconds after the correction, it will be corrected to thirty-second monitoring and feedback. In this way, by distinguishing feedback control, it can not only ensure the accuracy of real-time control, but also avoid the use of infrequently used devices during the implementation of control, which causes waste of resources and increases the cost of use.

[0039] The implementation end monitoring module monitors the processing extrusion end of the molding machine in real time, and sets the pressure value that produces abnormalities during processing, and sets them to level one, level two and level three respectively. The pressure value set at level one is the largest, and the pressure value set at level three is the smallest. After setting the pressure value, before each processing, the specific pressure values ​​of levels one, two and three are adjusted according to the pressure requirements of the specific processing. When the error generated during processing reaches level one, it will directly feedback and stop working. When it reaches level two and level three, it only needs to automatically perform fine-tuning to keep the positions of each pressure end consistent to ensure stability during processing. In this way, by comparing different levels, different adjustments can be made to different levels to improve the accuracy of head adjustment control.

[0040] The central control real-time processing unit includes a material judgment module and a multi-judgment module. Before processing, the material judgment module sets the models of different material plates in advance and marks them according to the hardness of the materials. The marking uses a combination of uppercase English letters and Arabic numerals. The larger the Arabic numerals, the greater the hardness of the material. The pressure value is adjusted according to different materials. By using different materials as adjustment parameters, the protection ability of the plates during adjustment can be improved.

[0041] Multiple judgment modules set the thickness of the plate to be processed and extruded in advance, and the thickness is set to two centimeters, four centimeters and six centimeters respectively. A custom adjustment library is set, and the custom adjustment library is adjusted according to the specific needs of use and adjusted to millimeters. At the same time, the size of the plate during processing is limited, and marked by A, B and C respectively, where A represents the largest size and C represents the smallest size. A custom setting library is also set to adjust according to the specific area required. In this way, adjustment and control can be carried out according to the customer's own needs, reducing limitations during use.

[0042] When the actual control adjustment unit is unable to adjust the working end and the control end, the manual adjustment unit communicates and warns with external experts and experienced employees, and then lets the experts and experienced employees make adjustments as soon as possible. The adjustment operation is divided into online adjustment operation and offline adjustment operation. Among them, expert adjustment adopts online remote operation and online remote guidance adjustment, while experienced employee adjustment adopts offline adjustment. An experienced employee can be responsible for two molding machines. This can ensure the molding machine's ability to handle problems when encountering problems and improve the stability of the molding machine during use.

[0043] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0044] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An automatic control system for a wall panel forming machine, characterized in that It includes working end layout unit, actual control drill unit, control end actual control feedback unit, central control real-time processing unit, actual control adjustment unit, periodic adjustment unit and manual adjustment unit: The working end layout unit places data acquisition sensors at each working end inside the molding machine, and the molding extrusion end uses a micro pressure controller to monitor the extrusion end, and the collected data is separately classified, collected and processed; The actual control rehearsal unit receives the data transmitted by the working end layout unit, and builds a virtual molding machine through three-dimensional modeling technology, and a virtual acquisition sensor is also placed on the virtual molding machine, and the virtual control end and the working end are marked corresponding to the real situation; The actual control feedback unit of the control end receives the data transmitted by the actual control drill unit, and compares and refers to the monitoring results of each working end and the implementation end according to the results of the implementation drill. When the monitoring end is in use, the data generated by the simulation drill in the simulation unit is used as a data reference when making the final judgment. The actual control feedback unit of the control end can also monitor the tiny devices and control end inside the molding machine in real time, and set up a database for abnormal processing of the control end inside the control end, and classify the abnormal problems of the control end into the first, second and third levels respectively, and formulate the first processing plan, the second processing plan and the third processing plan respectively; The central control real-time processing unit receives the data transmitted by the real-time feedback unit of the control end, integrates the information again when receiving the feedback information, and collects the material data of the plate during each pressing process; The implementation adjustment unit receives the data transmitted by the central control real-time processing unit, and when the data is received, directly adjusts and controls the working end and the control end of the molding machine, and when the adjustment and control are performed, the state data during the direct adjustment is saved; The cycle adjustment unit receives the data transmitted by the central control real-time processing unit, and records the number of adjustments each time the data is received and adjusted.

2. The automatic control system for a wall panel forming machine according to claim 1, characterized in that: The working end layout unit classifies and processes the collected data, and marks the outside of each sensor, wherein the working end sensors are marked in the form of English letters, and the working end is marked in Arabic numerals, and the collection sensors installed at the control end are uniformly classified into the control database, and the data collected by the working end are uniformly classified into the working end database, and after the control database and the working end database are established, the control database and the working end database are reviewed and improved by experts; The period adjustment unit is set with the number of adjustments, which are set to once every twenty days, twice every ten days, and three times every five days, respectively. Corresponding warning alarms are formulated, which are set to the first alarm, the second alarm, and the third alarm, respectively. The third alarm has the highest severity, while the first alarm has the lowest severity.

3. The automatic control system for a wall panel forming machine according to claim 1, characterized in that: After the virtual molding machine modeling is completed, the actual control rehearsal unit formulates the first simulation plan, the second simulation plan and the third simulation plan respectively, simulates and rehearses the formulated plans in turn, collects the problems generated in the process of the simulation rehearsal, and analyzes and processes the problem data in the collection process. After the analysis and processing is completed, the first treatment plan, the second treatment plan and the third treatment plan are formulated respectively corresponding to the first simulation plan, the second simulation plan and the third simulation plan, and the first simulation plan, the second simulation plan and the third simulation plan are re-simulated every half a month, and the first treatment plan, the second treatment plan and the third treatment plan are re-formulated every twenty days, and in the process of simulation formulation, reference is made to the problems generated in actual work.

4. The automatic control system for a wall panel forming machine according to claim 1, characterized in that: The actual control feedback unit at the control end includes a micro-monitoring module and an implementation end monitoring module. The micro-monitoring module monitors the small devices in the molding machine, and classifies the monitored objects during the monitoring process into commonly used and uncommonly used ones. Commonly used small devices are monitored in real time, and uncommonly used ones are monitored and fed back once every thirty seconds. If no abnormality occurs for twelve consecutive hours, it is automatically changed to one minute for monitoring and feedback. When no abnormality occurs for twenty-four hours, it is automatically changed to one minute and thirty seconds for monitoring and feedback. And so on. If an abnormality occurs in any of the above time periods, it is uniformly corrected to twenty seconds for monitoring and feedback. If no abnormality occurs within twenty seconds after the correction, it is corrected to thirty seconds for monitoring and feedback.

5. The automatic control system for a wall panel forming machine according to claim 1, characterized in that: The implementation end monitoring module monitors the processing extrusion end of the molding machine in real time, and sets the pressure value that produces abnormalities during processing, and sets them to level one, level two and level three respectively, among which the pressure value set at level one is the largest, and the pressure value set at level three is the smallest. After the pressure value is set, before each processing, the specific pressure values ​​of levels one, two and three are adjusted according to the pressure requirements of the specific processing. When the error generated during processing reaches level one, feedback will be directly given to stop working. When it reaches level two and level three, fine-tuning will be performed automatically to keep the positions of each pressure end consistent, thereby ensuring stability during processing.

6. The automatic control system for a wall panel forming machine according to claim 1, characterized in that: The central control real-time processing unit includes a material judgment module and a multi-judgment module. Before processing, the material judgment module sets the models of different material plates in advance and marks them according to the hardness of the materials. The marking uses a combination of uppercase English letters and Arabic numerals, and the larger the Arabic numerals, the greater the hardness of the material, and the pressure value is adjusted according to different materials.

7. The automatic control system for a wall panel forming machine according to claim 1, characterized in that: The multiple judgment modules set the thickness of the plate to be processed and extruded in advance, and the thickness is set to two centimeters, four centimeters and six centimeters respectively, and a custom adjustment library is set, and the custom adjustment library is adjusted according to the specific needs of use, and adjusted to millimeters. At the same time, the size of the plate during processing is limited, and it is marked by A, B and C respectively, where A represents the largest size and C represents the smallest size. A custom setting library is also set to adjust according to the area of ​​specific needs.

8. The automatic control system for a wall panel forming machine according to claim 1, characterized in that: When the actual control adjustment unit is unable to adjust the working end and the control end, the manual adjustment unit communicates and warns with external experts and experienced employees, and then allows the experts and experienced employees to make adjustments as soon as possible. The adjustment operation is divided into online adjustment operation and offline adjustment operation. Among them, expert adjustment adopts online remote operation and online remote guidance adjustment, while experienced employee adjustment adopts offline adjustment, and one experienced employee can be responsible for two molding machines.

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