A welding machine head and tail automatic centering control system and control method

Abstract

The application belongs to the technical field of automatic control, and provides a welding machine head and tail automatic centering control system and control method, the system comprises a high-definition camera system, a servo control system, a PLC control system and a position detection device, the high-definition camera system comprises a camera, a photosensitive source and a man-machine interface, the head and tail positions of the steel belt are sampled and monitored in real time, and the data is transmitted to the PLC control system through the high-definition camera system software, the PLC control system analyzes the positions of the head and tail, and compares them with the target positions, and sends control instructions to the servo control system according to the position comparison results; the execution structure of the servo control system comprises an electric push rod and a servo motor, the control system controls the electric push rod to realize the left-right alignment of the steel belt, and controls the servo motor to realize the front-back alignment of the steel belt; the high-definition camera system and the servo control system cooperate with the programmable controller to complete the accurate centering of the steel belt, ensure that the welding machine successfully completes the welding, improve the welding quality, reduce the failure rate, reduce the lost work time and the production capacity loss, and improve the unit operation rate and the product yield.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of automatic control, and relates to a steel strip centering of a decarburization and nitriding magnesium oxide coating unit for oriented silicon steel, in particular to a welding machine head and tail automatic centering control system and a control method. BACKGROUND

[0002] The main function of the decarburization and nitriding magnesium oxide coating unit for oriented silicon steel is to perform decarburization and nitriding treatment on the steel strip through high-temperature annealing, and then coat a magnesium oxide coating layer on the surface of the steel strip to provide an oriented silicon steel raw material roll with the magnesium oxide coating layer for a subsequent ring furnace. The welding machine plays a role in continuous production of the unit, and whether the welding quality can meet the standards becomes the key to the continuous production of the unit. Whether the head and tail of the front and rear steel rolls can be aligned with the center line of the unit with high precision and whether the head of the inlet and the tail of the outlet can be aligned are the most important for ensuring the welding quality and continuous operation of the production line.

[0003] The process flow of the welding machine is as follows:

[0004] 1) The tail of the upper steel roll is positioned to the welding machine;

[0005] 2) The welding machine outlet centering device centers the tail;

[0006] 3) The head of the lower steel roll is positioned to the welding machine;

[0007] 4) The welding machine inlet centering device centers the head;

[0008] 5) The head and tail are centered;

[0009] 6) After the system receives the centering completion signal of the head and tail, the welding machine is cut;

[0010] 7) The head and tail of the welding start to overlap;

[0011] 8) After the overlapping is completed, the welding machine welds the overlapping part;

[0012] 9) After the welding is completed, the unit starts to establish tension, the unit runs, and the welding machine returns to the original position to prepare for the next welding.

[0013] Since the oriented silicon steel is extremely thin, only 0.15mm-0.35mm, the centering form of the traditional narrow overlap welding machine is a single-side correction device, that is, there are two correction devices on one side of the welding machine, which respectively correct according to the photoelectric detection distance, and the centering precision is about 6mm. The centering process has low precision and long time, and is prone to cause the phenomena of steel strip edge correction, folding, pulling over the center line, etc., which leads to the phenomena of welding through, false welding, insufficient welding strength, etc. during the welding of the welding machine, directly causing the machine to be re-welded at a reduced speed or to be stopped, or even causing the steel strip to be stopped at the welding seam due to poor welding quality, which seriously affects the continuous and stable operation of the unit. SUMMARY

[0014] The application aims to provide a welding machine strip head and tail automatic centering control system and control method, which can realize accurate centering of the strip by the cooperation of the high-definition camera system and the servo control system and the programmable controller, ensure the smooth completion of welding by the welding machine, improve the weld quality, reduce the failure rate, reduce the lost time and production capacity loss, and improve the unit operation rate and product yield.

[0015] The application adopts the technical scheme to realize the above-mentioned purpose:

[0016] The application adopts the technical scheme to realize the above-mentioned purpose:

[0017] The high-definition camera system includes an entrance operation side high-definition camera system and an entrance centering high-definition camera system, an exit operation side high-definition camera system and an exit centering camera system.

[0018] Further, the control method of the centering control system is:

[0019] The distance between the center line of the operation side high-definition camera system and the center line of the unit is ES1, the width of the strip is EW1, the distance between the strip head edge shot by the operation side high-definition camera system and the center line of the operation side high-definition camera system is ES2, the distance between the farthest strip edge in the shooting range of the centering high-definition camera system and the center line of the operation side high-definition camera system is ES3, and the distance between the strip head edge and the zero reference line of the electric push rod is OF.

[0020] When the strip head reaches the detection position of the high-definition camera system, ES2 and ES3 are obtained by the position detection device and sent to the PLC control system.

[0021] When ES2=ES3, the steel plate is in the center line of the unit, and the electric push rod does not need to act; when ES2>ES3, the steel strip is deviated to the operation side, OF=ES1-ES2-ES1 / 2; when ES2<ES3, the steel strip is deviated to the drive side, OF=ES1 / 2-ES1+ES2; the PLC control system further calculates the data of the electric push rod to be acted according to this, and sends it to the electric push rod to complete the action, and the high-definition camera system returns the real-time ES2 and ES3 data in the process until ES2=ES3.

[0022] When the centering of the inlet and outlet steel strips is completed, longitudinal alignment is performed.

[0023] The distance between the head edge of the strip steel photographed by the high-definition camera system on the operation side of the inlet area centering device and the center line of the high-definition camera system on the operation side is ZE2, and the distance between the farthest edge of the strip steel in the photographing range of the inlet area centering high-definition camera system and the center line of the high-definition camera system on the operation side is ZE3.

[0024] The distance between the head edge of the strip steel photographed by the high-definition camera system on the operation side of the outlet area centering device and the center line of the high-definition camera system on the operation side is ZD2, and the distance between the farthest edge of the strip steel in the photographing range of the outlet area centering high-definition camera system and the center of the high-definition camera system on the operation side is ZD3.

[0025] When ZE2>ZD2, the PLC control system drives the servo motor to drive the inlet centering device to move to the operation side based on the ZD2 data until ZE2=ZD2, and conversely, when ZE2<ZD2, the servo driver drives the inlet centering device to move to the drive side based on the ZD2 data until ZE2=ZD2, and the front and rear centering of the steel strip is completed. After that, it is checked whether ZE3 and ZD3 are equal, and if they are equal, the longitudinal alignment is completed.

[0026] Further, the position detection device adopts a position sensor, which is arranged at the outer corner position of the drive side of the welding machine centering device through a fixed support.

[0027] Further, the fixed support includes a sliding rail frame, a sliding rail fixed frame and a sensor fixed frame, the sliding rail fixed frame is fixedly connected with the sliding rail frame, the sliding rail frame is slidably connected with the sensor fixed frame through screws clamped into sliding grooves, the sensor fixed frame is processed with a long groove, the screws can slide in the long groove, and the position sensor is connected to the sensor fixed frame. The position of the position sensor can be adjusted by adjusting the positions of the screws in the sliding grooves and the long groove.

[0028] The beneficial effects of the present application are: the strip head and tail are automatically centered controlled by the high-definition camera system, the servo control system and the position detection device, the centering accuracy is improved to 2mm, the welding machine is ensured to be successfully completed, the weld quality is improved, the failure rate is reduced, the off-work time and the production capacity loss are reduced, the unit operation rate and the product yield are improved; the application of the high-definition camera system upper software and the man-machine interface and the exchange of field data can make the maintenance personnel remotely view the data, the maintenance is more convenient, the position sensor of the position detection device is lower in cost than the traditional displacement sensor, and the maintenance is more convenient. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 is the system control principle diagram of the present application;

[0030] Figure 2 is a position detection device fixed support structure schematic diagram;

[0031] Figure 3 is a welding machine high-definition camera system structure schematic diagram;

[0032] Figure 4 is the control logic diagram of the system;

[0033] Figure 5 is a welding machine entrance strip deviation operation side schematic diagram;

[0034] Figure 6 is a welding machine entrance strip deviation rotation side schematic diagram;

[0035] Figure 7 is a welding machine entrance and exit strip longitudinal alignment schematic diagram;

[0036] In the figure, 1, steel strip; 2, high-definition camera system; 21, camera, 22, photosensitive source; 23, man-machine interface; 201, 3, PLC control system; 4, servo control system; 5, position detection device; 51, position sensor; 52, slide rail frame; 53, slide rail fixed frame; 54, sensor fixed frame; 55, slide rail sliding groove; 56, screw; 57, long groove; 6, electric push rod zero reference line; 7, steel plate center line; 8, unit center line; 9, servo motor. DETAILED DESCRIPTION

[0037] The present application will be further described below in combination with the drawings and examples:

[0038] A welding machine strip head and tail automatic centering control system, such as Figure 1As shown, including high-definition camera system 2, PLC control system 3 and servo control system 4 and position detection device 5, high-definition camera system 2 includes camera 21, photosensitive source 22 and human-computer interaction interface 23, high-definition camera system 2 samples and monitors the head and tail position of the steel strip in real time, and transmits the data to PLC control system 3 through high-definition camera system software, PLC control system 3 analyzes the position of the head and tail, and compares with the target position, and sends control instructions to servo control system 4 according to the position comparison result; The execution structure of servo control system 4 includes electric push rod and servo motor, and the control system controls the electric push rod to realize the left-right alignment of the steel strip, and controls the servo motor to realize the front-back alignment of the steel strip.

[0039] PLC control system 3 adopts Siemens S7-1500, camera adopts Bonner VE201G1A visual sensor, and high-definition camera system software adopts processing visual management software Banner Vision Manager;

[0040] Position detection device 5 adopts position sensor 51, which is arranged at the outer corner position of the transmission side of the welding machine centering device through a fixed support. Figure 2 As shown, the fixed support includes slide rail frame 52, slide rail fixed frame 53 and sensor fixed frame 54, the slide rail fixed frame 53 is fixedly connected with the slide rail frame 52 for fixing the slide rail frame 52, the slide rail frame 52 is slidably connected with the sensor fixed frame 54 through screws 56 clamped into slide rail sliding grooves 55, the sensor fixed frame 54 is machined with a long groove 57, the screws 56 can slide in the long groove 57, the position sensor 51 is connected on the sensor fixed frame 54, and the position of the position sensor 51 can be adjusted by adjusting the position of the screws 56 in the slide rail sliding grooves 55 and the long groove 57, so as to be suitable for detecting the position of the steel strip.

[0041] High-definition camera system 2 includes entrance operation side high-definition camera system 201 and entrance centering high-definition camera system 202, exit operation side high-definition camera system 203 and exit centering camera system 204, as shown. Figure 3 High-definition camera system data is loaded, transmitted to human-computer interaction interface, and at the same time, the data is analyzed and processed by PLC control system to issue control servo control system signal or stored in storage for human-computer interaction interface query and display; The system control logic is as shown. Figure 4

[0042] The principle of the entrance centering and centering control device is the same, taking the entrance centering as an example, the control algorithm of the centering control device is:

[0043] ​The distance between the center line of the entry operation side high-definition camera system 201 and the center line of the machine set is ES1, the width of the steel strip is EW1, the distance between the edge of the strip head photographed by the operation side high-definition camera system 201 and the center line of the operation side high-definition camera system 201 is ES2, the distance between the farthest edge of the strip in the range photographed by the entry high-definition camera system 202 and the center line of the operation side high-definition camera system 201 is ES3, and the distance between the edge of the strip head and the zero reference line 6 of the electric push rod is OF; as shown in Figure 5 and Figure 6 .

[0044] When the head of the steel strip reaches the detection position of the entry high-definition camera system 202, ES2 and ES3 are obtained by the position detection device 5 and sent to the PLC control system.

[0045] When ES2=ES3, the center line 7 of the steel plate is on the center line 8 of the machine set, and the electric push rod does not need to act; when ES2>ES3, the steel strip is deviated to the operation side, OF=ES1-ES2-ES1 / 2; when ES2<ES3, the steel strip is deviated to the drive side, OF=ES1 / 2-ES1+ES2; the PLC control system further calculates the data of the action of the electric push rod according to this and sends the data to the electric push rod to complete the action, and the high-definition camera system returns the real-time ES2 and ES3 data in the process until ES2=ES3.

[0046] When the entry and exit strip centering is completed, longitudinal alignment is performed, as shown in Figure 7 .

[0047] The distance between the edge of the strip head photographed by the operation side high-definition camera system 201 of the entry area centering device and the center line of the operation side high-definition camera system 201 is ZE2, and the distance between the farthest edge of the strip in the range photographed by the entry area centering high-definition camera system 202 and the center line of the operation side high-definition camera system 201 is ZE3.

[0048] The distance between the edge of the strip head photographed by the operation side high-definition camera system 203 of the exit area centering device and the center line of the operation side high-definition camera system 203 is ZD2, and the distance between the farthest edge of the strip in the range photographed by the exit area centering high-definition camera system 204 and the center of the operation side high-definition camera system 203 is ZD3.

[0049] When ZE2>ZD2, the PLC control system drives the servo motor to drive the entry centering device to move to the operation side as a reference based on the ZD2 data until ZE2=ZD2, and conversely, when ZE2

Claims

1. A control method for an automatic centering control system for a welding machine with both head and tail sections, characterized in that: The control system includes a high-definition camera system, a servo control system, a PLC control system, and a position detection device. The high-definition camera system includes a camera, a light source, and a human-machine interface, which samples and monitors the positions of the leading and trailing ends of the steel strip in real time, and transmits the data to the PLC control system through the high-definition camera system software. The PLC control system analyzes the positions of the leading and trailing ends and compares them with the target positions, and issues control commands to the servo control system according to the position comparison results; the execution structure of the servo control system includes an electric push rod and a servo motor. The control system controls the electric push rod to align the steel strip left and right, and controls the servo motor to align the steel strip front and back; the high-definition camera system includes an entrance operation side high-definition camera system, an entrance centering high-definition camera system, an exit operation side high-definition camera system, and an exit centering camera system; the control method of the control system includes: 1) The centering actions of the steel strip at the entrance and exit of the welder: Let the distance between the center line of the operation side high-definition camera system and the center line of the unit be ES1, the width of the steel strip be EW1, the distance between the edge of the steel strip head captured by the operation side high-definition camera system and the center line of the operation side high-definition camera system be ES2, the distance between the edge of the steel strip at the farthest end within the capture range of the centering high-definition camera system and the center line of the operation side high-definition camera system be ES3, and the distance between the edge of the steel strip head and the zero position reference line of the electric push rod be OF; After the leading end of the steel strip reaches the detection position of the high-definition camera system, ES2 and ES3 are obtained through the position detection device and sent to the PLC control system; When ES2 = ES3, the center line of the steel plate is on the center line of the unit, and the electric push rod of the execution structure does not need to act; When ES2 > ES3, the steel strip deviates towards the operation side, OF = ES1 - ES2 - ES1 / 2, or when ES2 < ES3, the steel strip deviates towards the drive side, OF = ES1 / 2 - ES1 + ES2; the PLC control system calculates the data for the electric push rod to act and issues it to the electric push rod to complete the action. During the process, the high-definition camera system returns the real-time ES2 and ES3 data until ES2 = ES3, and the horizontal centering is completed; 2) When the centering of the steel strip at the entrance and exit is all completed, the longitudinal alignment action is carried out: Let the distance between the edge of the steel strip head captured by the operation side high-definition camera system of the centering device in the entrance area and the center line of the operation side high-definition camera system be ZE2, and the distance between the edge of the steel strip at the farthest end within the capture range of the centering high-definition camera system in the entrance area and the center line of the operation side high-definition camera system be ZE3; The distance between the edge of the steel strip head captured by the operation side high-definition camera system of the centering device in the exit area and the center line of the operation side high-definition camera system is ZD2, and the distance between the edge of the steel strip at the farthest end within the capture range of the centering high-definition camera system in the exit area and the center of the operation side high-definition camera system is ZD3; When ZE2 > ZD2, based on the ZD2 data, the PLC control system drives the servo motor to drive the entire inlet centering device to move towards the operator side until ZE2 = ZD2. On the contrary, when ZE2 < ZD2, based on ZD2, the servo driver drives the entire inlet centering device to move towards the drive side until ZE2 = ZD2, completing the front and back centering of the steel strip. After that, check whether the data of ZE3 and ZD3 are equal. If they are equal, the longitudinal alignment is completed.

2. The control method for an automatic centering control system for a welding machine with head and tail as described in claim 1, characterized in that: The position detection device of the control system uses a position sensor and is arranged at the outer corner position of the drive side of the welder centering device through a fixed bracket.

3. The control method for an automatic centering control system for a welding machine with head and tail as described in claim 2, characterized in that: The fixed bracket includes a slide rail frame, a slide rail fixing frame, and a sensor fixing frame. The slide rail fixing frame is fixedly connected to the slide rail frame to fix the slide rail frame. The slide rail frame is slidably connected to the sensor fixing frame through screws that are inserted into the slide rail chute. A long groove is machined on the sensor fixing frame, and the screws can slide within the long groove. The position sensor is connected to the sensor fixing frame. The position adjustment of the position sensor can be achieved by adjusting the positions of the screws in the slide rail chute and the long groove.

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