Intelligent roller groove grinding device and control method thereof

Abstract

The invention relates to an intelligent roller groove grinding device and a control method thereof. The device comprises a roller welding mechanism and a roller supporting mechanism. The roller welding mechanism comprises a base, a moving unit and a welding wire clamping unit. The moving units comprise the first moving unit used for driving the welding wire clamping unit to move in the X-axis direction and the second moving unit used for driving the welding wire clamping unit to move in the Y-axis direction. The first moving unit comprises a first lead screw, a first sliding block and a first stepping motor. The second moving unit comprises a second lead screw, a second sliding block and a second stepping motor. The roller supporting mechanism comprises a roller way unit and an alternating current motor used for driving the roller way unit to rotate. The stepping motor and the belt are used for driving the lead screw to rotate, the lead screw drives the welding wire clamping unit to move in the X-axis direction or the Y-axis direction, the PLC is adopted for designing the moving track of the welding tongs, automatic feeding and walking of the welding tongs clamping a welding wire in the welding process are achieved, and therefore automatic welding of a roller is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of bar rolling in the metallurgical industry, and in particular to an intelligent roller groove grinding device and a control method thereof. Background Art

[0002] In the metallurgical industry, bar rolling is the process of processing heated billets into the desired size and shape through a series of rotating rolls. When the rolling specifications need to be changed, the surface of the newly installed rolls is usually smooth, which may make it difficult for the first billet to bite smoothly, thus affecting production efficiency and possibly causing material waste or equipment damage.

[0003] In order to solve the above problems, the traditional method is for operators to hold welding tongs and weld densely packed welds on the rotating rollers to increase friction and prevent the steel from biting and causing waste. However, the existing method has the following problems:

[0004] (1) Sparks generated during welding and high-speed rotation of the rollers pose a great safety risk to operators, who face the risk of serious burns, scalds and other mechanical injuries. Sparks generated during welding can splash onto operators, easily damaging clothing or even causing harm to the human body. Moreover, under the action of high welding current, the welding tongs will become hot and scalding if welding is continued for 3 minutes, which is very dangerous. In addition, welding on rotating rollers can easily cause injuries from being squeezed by the rollers.

[0005] (2) The roller groove grinding operation is done manually online. Manual operation is difficult to ensure uniform distribution of weld points, which affects the quality of products in the subsequent rolling process. When welding on the rotating roller, the operator holds the welding clamp and moves it left and right while moving forward. If the movement is too fast, it will cause arc failure and welding leakage; if the movement is too slow, it will cause larger weld points and unevenness, and the welding quality cannot be guaranteed.

[0006] (3) When performing roller groove grinding, the operator should hold the The welding tongs for round steel should be kept about 1.3 meters from the ground. The operator should keep an eye on the roller while carrying a load (including the weight of the welding gun, welding wire, and round steel) of 1.5 kg. Holding heavy objects (such as welding tongs) in a specific posture for a long time for delicate operations can easily cause fatigue to the worker and increase the possibility of human error.

[0007] Therefore, it is necessary to develop a new intelligent roll groove grinding device to improve the current bar rolling production process, reduce safety hazards, and ensure the stability and efficiency of the rolling process. Summary of the invention

[0008] In order to solve the deficiencies in the prior art, an object of the present invention is to provide an intelligent roller groove grinding device and a control method thereof.

[0009] To achieve the above object, the present invention adopts the following technical solutions:

[0010] The invention comprises an intelligent roller groove grinding device, which comprises a roller welding mechanism and a roller supporting mechanism.

[0011] The roller welding mechanism comprises a base, a moving unit installed above the base, and a welding wire clamping unit installed on the moving unit.

[0012] The moving unit includes a first moving unit for driving the welding wire clamping unit to move along the X-axis direction and a second moving unit for driving the welding wire clamping unit to move along the Y-axis direction; the first moving unit includes a first lead screw, a first slider connected to the first lead screw, and a first stepper motor for driving the first lead screw to rotate; the second moving unit includes a second lead screw, a second slider connected to the second lead screw, and a second stepper motor for driving the second lead screw to rotate.

[0013] The roller support mechanism comprises a roller table unit and an AC motor for driving the roller table unit to rotate.

[0014] As a further improvement of the above technical solution, the device also includes a PLC controller; the output end of the PLC controller is respectively connected to the control ends of the first stepper motor, the second stepper motor, and the AC motor; the PLC controller is respectively connected to the first stepper motor, the second stepper motor, and the AC motor through a drag chain cable; the first stepper motor, the second stepper motor, and the AC motor are connected to a power supply through a drag chain cable.

[0015] As a further improvement of the above technical solution, the second lead screw is installed on the top of the base, and two first bearing seats are installed on the top of the base, and the first bearing seats are installed in the first bearings; the two ends of the screw of the second lead screw are respectively installed in the first bearings in the two first bearing seats; and a plurality of limit blocks are installed on the base.

[0016] As a further improvement of the above technical solution, a second slide rail is also installed on the top of the base; the second slide rail passes through the second sliding block; there are two second slide rails, and the two second slide rails are respectively located on the left and right sides of the second lead screw.

[0017] As a further improvement of the above technical solution, the first movable unit is installed above the second movable unit; the first lead screw is installed on the top of the second slider; two second bearing seats are installed on the top of the second slider, and second bearings are installed in the second bearing seats; both ends of the screw of the first lead screw are respectively installed in the second bearings of the two second bearing seats; the welding wire clamping unit is installed above the first slider.

[0018] As a further improvement of the above technical solution, a fixing seat is sleeved on the second slide rail; the fixing seat and the second slide rail are clearance-matched; and the second sliding block is fixedly connected to the fixing seat.

[0019] As a further improvement of the above technical solution, the roller unit includes a first roller and a second roller arranged side by side; the first roller and the second roller are respectively installed on a support; the first roller is driven to rotate by the AC motor, and the second roller rotates driven by the first roller; the AC motor is a three-phase AC motor.

[0020] As a further improvement of the above technical solution, the first lead screw includes a first screw and a first nut sleeved on the first screw and threadedly connected to the first screw; the first slider is fixedly connected to the first nut; the output end of the first stepper motor is connected to the first screw, or the output end of the first stepper motor is matched with the first screw through a first belt. The second lead screw includes a second screw and a second nut sleeved on the second screw and threadedly connected to the second screw; the second slider is fixedly connected to the second nut; the output end of the second stepper motor is connected to the second screw, or the output end of the second stepper motor is matched with the second screw through a second belt.

[0021] As a further improvement of the above technical solution, the device also includes a first stepper motor driver, a second stepper motor driver, a remote controller, a remote control receiver, a display screen and a power supply. The power supply is used to supply power to the PLC controller, the first stepper motor driver, the second stepper motor driver, the remote control receiver and the display screen.

[0022] As a further improvement of the above technical solution, the input end of the first stepper motor driver is connected to the output end of the PLC controller, and the output end of the first stepper motor driver is connected to the control end of the first stepper motor; the input end of the second stepper motor driver is connected to the output end of the PLC controller, and the output end of the second stepper motor driver is connected to the control end of the second stepper motor; the first stepper motor driver controls the movement of the first stepper motor through a control line, and the second stepper motor driver controls the movement of the second stepper motor through a control line.

[0023] As a further improvement of the above technical solution, the PLC controller is connected to the remote control receiver via a communication line; the remote control receiver is wirelessly connected to the remote controller; and the PLC controller is connected to the display screen via a data bus.

[0024] As a further improvement of the above technical solution, the PLC controller adopts the programmable logic controller FX2nPLC, and the touch screen adopts the Weiluntong touch screen TK6051IP.

[0025] The present invention also includes a control method for the above-mentioned intelligent roller groove grinding device, which comprises the following steps:

[0026] The PLC controller sends a control signal to control the first stepper motor to rotate, the first stepper motor drives the first lead screw to rotate, and the first lead screw drives the first slider to move along the X-axis direction; the PLC controller sends a control signal to control the second stepper motor to rotate, the second stepper motor drives the second lead screw to rotate, and the second lead screw drives the second slider to move along the Y-axis direction; by controlling the movement of the first slider and the second slider, the welding wire clamping unit is controlled to move along the X-axis direction or the Y-axis direction to achieve the adjustment of the welding wire trajectory.

[0027] Compared with the prior art, the advantages of the present invention are:

[0028] The intelligent roller groove grinding device of the present invention drives the lead screw to rotate by a stepper motor, and the lead screw drives the wire clamping unit (such as welding clamp) to move along the X-axis direction or the Y-axis direction. The PLC controller is used to design the running track of the welding clamp, which is used to realize the automatic feeding and movement of the welding clamp holding the welding wire during the welding process, thereby realizing the automatic welding of the roller. The intelligent roller groove grinding machine of the present invention can be modified according to production requirements to meet the needs of different similar equipment of various enterprises. The intelligent roller groove grinding machine of the present invention has a simple structure and is easy to operate, which realizes the automatic welding operation of the roller, improves the operation efficiency, and reduces safety hazards. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the mechanical transmission system of the intelligent roller groove grinding device in the present invention;

[0030] Figure 2 This is the electrical control principle diagram of the intelligent roller groove grinding device in the present invention;

[0031] Figure 3 It is a block diagram of the electrical control system of the intelligent roller groove grinding device in the present invention;

[0032] Figure 4 This is a physical picture of the electrical control box of the intelligent roller groove grinding device in the present invention.

[0033] in:

[0034] 1. Wire clamping unit, 2. First slider, 3. First lead screw, 4. First bearing seat, 5. First stepper motor, 6. Drag chain cable, 7. Second slider, 8. Fixed seat, 9. Second lead screw, 10. Limit block, 11. Base, 12. Second stepper motor, 13. Second slide rail, 14. Second roller, 15. Support, 16. AC motor, 17. First roller, 18. Roller, 19. PLC controller, 20. First stepper motor driver, 21. Second stepper motor driver, 22. Display screen, 23. Remote control receiver, 24. Remote control, 25. Power supply. DETAILED DESCRIPTION

[0035] The present invention will be further described below in conjunction with the accompanying drawings and embodiments:

[0036] It should be noted that the following detailed descriptions are exemplary and are intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those commonly understood by those skilled in the art to which the present invention belongs.

[0037] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0038] In the absence of conflict, the embodiments of the present invention and the features of the embodiments may be combined with each other.

[0039] According to the nature and mode of roller groove grinding operation in a rod and wire workshop of the metallurgical industry, the present invention designs and implements an intelligent roller groove grinding device, which can replace the manual groove grinding operation and realize automatic welding of the roller.

[0040] like Figure 1An intelligent roller groove grinding device is shown, which includes a roller welding mechanism and a roller supporting mechanism; the roller welding mechanism includes a base 11, a mobile unit installed above the base 11, and a welding wire clamping unit 1 installed on the mobile unit; the mobile unit includes a first mobile unit for driving the welding wire clamping unit 1 to move along the X-axis direction and a second mobile unit for driving the welding wire clamping unit 1 to move along the Y-axis direction; the first mobile unit includes a first lead screw 3, a first slider 2 connected to the first lead screw 3, and a first stepping motor 5 for driving the first lead screw 3 to rotate; the second mobile unit includes a second lead screw 9, a second slider 7 connected to the second lead screw 9, and a second stepping motor 12 for driving the second lead screw 9 to rotate. The roller supporting mechanism includes a roller unit and an AC motor 16 for driving the roller unit to rotate.

[0041] The base 11 is used to support and fix the entire roller groove grinding device; as the basic structure of the entire device, the base 11 provides the necessary mechanical support to ensure that all components installed thereon can work stably. It also carries the drag chain cable and other key components to provide power connection for the motor and other electrical components. The drag chain cable 6 is installed on one side of the base 11, moves with the lead screw in the X-axis direction, and supplies power to the first stepper motor 5. The limit block 10 is installed at both ends of the second slide rail 13; the first stepper motor 5 is installed in the middle of the base 11 to provide power for the rotation of the first lead screw 3 and the sliding of the first slider 2. The first lead screw 3 is installed above the middle of the base 11 and is connected to the output end of the first stepper motor 5. The first stepper motor 5 drives the first lead screw to rotate, thereby driving the first slider 2 to move along the X direction. The other end of the first lead screw 3 is connected to the bearing in the bearing seat, and the bearing plays a supporting role. The first slider 2 is mounted on the second slider 7 and connected to the second slide rail 13 through the fixing seat 8; the second stepper motor 12 is mounted at one end of the second slide rail 13; the second lead screw is mounted between the two second slide rails 13 and connected to the output end of the second stepper motor 12, and can drive the second slider 7 to move. The welding wire clamping unit 1 is mounted on one side of the first slider 2 and can realize X-direction movement with the movement of the first slider 2. By controlling the movement of the welding wire clamping unit 1, it can be ensured that the welding wire is in contact with the surface of the roller 18. The roller is placed between the first roller 17 and the second roller 14, wherein the first roller 17 rotates with the rotation of the AC motor 16, and the second roller 14 is an auxiliary transmission, and rotates with the first roller 17 driving the roller to rotate. The first roller 17, the second roller 14 and the roller are ensured to have accurate relative positions through the support 15.

[0042] The stepper motor is used to drive the lead screw to rotate and realize the automatic feeding and movement of the welding clamp due to its advantages such as simple control and convenient speed regulation. This design improves the automation degree of the groove grinding process, reduces manual operation, and improves efficiency and safety. The first moving unit and the second moving unit are used to realize the movement of the welding wire clamping unit along the X-axis and Y-axis directions, and provide precise positioning in two-dimensional space to meet the needs of roller groove grinding at different positions. The first stepper motor is driven to realize the movement of the welding wire clamping unit along the X-axis direction. This design allows the welding wire clamping unit to be precisely positioned in the horizontal direction to realize accurate groove grinding on the roller surface. The second stepper motor is driven to realize the movement of the welding wire clamping unit 1 along the Y-axis direction, which enables the welding wire clamping unit to be adjusted in the vertical direction, further enhancing the flexibility and accuracy of the groove grinding.

[0043] It can be seen from the above technical solution that the stepper motor drives the lead screw to rotate, so as to realize the precise movement of the welding wire clamping unit in two dimensions. This design allows the welding wire clamping unit to accurately reach the specified position according to the preset path, ensuring the welding quality while also improving the degree of automation. In the first moving unit (X axis), the first lead screw 3 is driven by the first stepper motor 5 to move the welding wire clamping unit along the X direction. This design is used to control the lateral position adjustment of the welding wire relative to the roller surface. In the second moving unit (Y axis), the second lead screw 9 is driven by the second stepper motor 12 to move the welding wire clamping unit along the Y direction. This design is used to control the longitudinal position adjustment of the welding wire relative to the roller surface. The first slider 2 drives the first lead screw 3 to rotate through the first stepper motor and the first belt, so as to realize the movement of the adjustable welding wire clamping unit 1 along the X axis through the first slider 2. The second slide rail 13 is installed on the second slider 7, and the second lead screw 9 is driven to rotate through the second stepper motor 12 and the second belt, so as to realize the movement of the adjustable welding wire clamping unit 1 along the Y axis. The intelligent roller groove grinding device described in the present invention adopts a stepping motor to drive the lead screw to rotate, and the lead screw drives the welding clamp to move. The running trajectory of the welding clamp is controlled by PLC to realize automatic feeding and movement of the welding clamp during the welding process, thereby realizing automatic welding of pitting on the roller surface, thereby replacing manual work.

[0044] As a further improvement of the above technical solution, the first lead screw 3 includes a first screw rod and a first nut sleeved on the first screw rod and threadedly connected to the first screw rod; the first slider 2 is fixedly connected to the first nut. The output end of the first stepper motor 5 is connected to the first screw rod, or the output end of the first stepper motor 5 is coupled to the first screw rod through a first belt.

[0045] As a further improvement of the above technical solution, the second lead screw 9 includes a second screw rod and a second nut sleeved on the second screw rod and threadedly connected to the second screw rod; the second slider 7 is fixedly connected to the second nut. The output end of the second stepper motor 12 is connected to the second screw rod, or the output end of the second stepper motor 12 is coupled to the second screw rod through a second belt.

[0046] As a further improvement of the above technical solution, the device also includes a PLC controller 19; the output end of the PLC controller 19 is respectively connected to the control end of the first stepper motor 5, the second stepper motor 12, and the AC motor 16; the PLC controller 19 is respectively connected to the first stepper motor 5, the second stepper motor 12, and the AC motor 16 through a drag chain cable 6. The first stepper motor 5, the second stepper motor 12, and the AC motor 16 are also connected to a power source 25 through a drag chain cable 6. The AC motor 16 adopts a three-phase AC motor 16, which is used to drive the roller unit to rotate and realize the rotation of the roller so that the welding wire clamping unit can grind the surface of the roller. The drag chain cable is used to supply power and transmit signals to the moving parts, and has a certain flexibility, and can move with the slider without affecting its normal operation. As the core of the control system, the PLC controller 19 is responsible for receiving instructions from the operation interface (such as a touch screen or a remote control) and coordinating the actions of each actuator. It can accurately control the speed, acceleration and final position of the motor, thereby realizing complex motion trajectory planning. In addition, PLC can also monitor system status and provide functions such as fault diagnosis, enhancing the reliability and safety of the system.

[0047] As a further improvement of the above technical solution, the roller table unit includes a first roller table 17 and a second roller table 14 arranged side by side; the first roller table 17 and the second roller table 14 are respectively installed on a support 15. The roller tables are driven to rotate by an AC motor so that the rollers placed therebetween can be welded evenly. The double roller table design not only provides stable support, but also can rotate synchronously with the main drive to ensure the smooth operation of the rollers.

[0048] As a further improvement of the above technical solution, a plurality of limit blocks 10 are installed on the base 11; the limit blocks 10 are used to limit in the Y direction. The limit blocks 10 can limit the slider to prevent the slider from falling off the slide rail.

[0049] As a further improvement of the above technical solution, the second lead screw 9 is installed on the top of the base 11, and two first bearing seats 44 are installed on the top of the base 11, and the first bearing seats 44 are installed with first bearings. The two ends of the screw of the second lead screw 9 are respectively installed in the first bearings in the two first bearing seats 44. The bearings are used to support the mechanical rotating body, reduce the friction coefficient during the movement of the lead screw, and ensure the rotation accuracy. In this embodiment, the bearings are used to fix the lead screw so that it can only rotate and control its axial and radial movement.

[0050] As a further improvement of the above technical solution, a second slide rail 13 is further installed on the top of the base 11; the second slide rail 13 passes through the second slider 7, and during the sliding of the second slider 7 along the Y-axis direction, the second slide rail 13 plays a supporting, guiding and limiting role, maintaining the stability of the sliding of the second slider 7 along the Y-axis direction. There are two second slide rails 13, and the two second slide rails 13 are respectively located on the left and right sides of the second lead screw 9.

[0051] As a further improvement of the above technical solution, the first moving unit is installed above the second moving unit; the first lead screw 3 is installed on the top of the second slider 7; two second bearing seats are installed on the top of the second slider 7, and second bearings are installed in the second bearing seats. The two ends of the screw of the first lead screw 3 are respectively installed in the second bearings of the two second bearing seats. The welding wire clamping unit 1 is installed above the first slider 2. The welding wire clamping unit 1 is used to fix and guide the welding wire to ensure that it maintains the correct posture and has good contact with the roller surface during welding. The unit needs to move with the slider to adapt to the welding requirements at different positions.

[0052] In this embodiment, the second mobile unit is mounted on the base 11, the first mobile unit is mounted above the second mobile unit, and the wire clamping unit 1 is mounted above the first mobile unit. In addition, the first mobile unit can also be mounted on the base 11, the second mobile unit can be mounted above the first mobile unit, and the wire clamping unit 1 can be mounted above the second mobile unit. The bearing is used to support the mechanical rotating body, reduce the friction coefficient during the movement of the screw, and ensure the rotation accuracy. In this embodiment, the bearing is used to fix the screw so that it can only rotate, while controlling its axial and radial movement.

[0053] As a further improvement of the above technical solution, a fixing seat 8 is sleeved on the second slide rail 13; the fixing seat 8 is clearance-matched with the second slide rail 13; and the second slider 7 is fixedly connected to the fixing seat 8. The second slide rail 13 is installed on the base 11 to provide a running track for the movement of the second slider 7.

[0054] As a further improvement of the above technical solution, the device also includes a first stepper motor driver 20, a second stepper motor driver 21, a remote controller 24, a remote control receiver 23, a display screen 22 and a power supply 25. The power supply 25 is used to supply power to the PLC controller 19, the first stepper motor driver 20, the second stepper motor driver 21, the remote control receiver 23 and the display screen 22. The input end of the first stepper motor driver 20 is connected to the output end of the PLC controller 19, and the output end of the first stepper motor driver 20 is connected to the control end of the first stepper motor. The input end of the second stepper motor driver 21 is connected to the output end of the PLC controller 19, and the output end of the second stepper motor driver 21 is connected to the control end of the second stepper motor. The PLC controller 19 is signal-connected to the remote control receiver 23. The remote control receiver 23 is wirelessly connected to the remote controller 24. The input and output ends of the display screen 22 are connected to the input and output ends of the PLC controller 19. The first stepper motor is a feed motor, and the second stepper motor is a travel motor.

[0055] The PLC controller 19 adopts a programmable logic controller FX2nPLC, and the touch screen adopts a Weiluntong touch screen TK6051IP. The programmable logic controller FX2nPLC is connected to the Weiluntong touch screen TK6051IP through the PROFBUS data bus, and the programmable logic controller FX2nPLC is connected to the remote control receiver 23 through a communication line. The AC / DC 24V power supply 25 provides power supply 25 support for the programmable logic controller FX2nPLC, the Weiluntong touch screen TK6051IP, the remote control receiver 23, the first stepper motor driver 20, and the second stepper motor driver 21 through the power supply 25 line. The first stepper motor driver 20 controls the movement of the first stepper motor through the control line, and the second stepper motor driver 21 controls the movement of the stepper motor through the control line. The programmable logic controller FX2nPLC, Weiluntong touch screen TK6051IP, AC / DC 24V power supply 25, the first stepper motor driver 20, the second stepper motor driver 21, the first stepper motor, the second stepper motor, the button with indicator light, the conversion switch, the wiring terminal, etc. are integrated in the distribution box through the control line distribution panel to form a complete electric control system. As the core of the electrical control system, the precise control of the stepper motor, AC motor, etc. is achieved through PLC programming. The use of PLC improves the flexibility and programmability of the control system, so that the groove grinding process can be customized according to different roller characteristics. The integrated electric control system ensures effective communication and coordinated operation between all electrical components. For example, the stepper motor driver can receive commands from the PLC and convert them into appropriate current to drive the motor; the remote control receiver allows remote control of the equipment, which increases the flexibility of operation.

[0056] The intelligent roller groove grinding device described in the present invention realizes manual and automatic integrated control. By changing the data parameters on the touch screen, the running speed of the stepper motor can be regulated and the groove grinding time can be set. A stepper motor is used to drive the lead screw to rotate, and the welding clamp is driven to move by the lead screw rotation. By writing a PLC program, the required welding clamp running trajectory is realized, thereby realizing the automatic feeding and walking of the welding clamp during the welding process, and realizing the automatic welding of pitting on the surface of the roller, thereby replacing manual work. The operator can operate through three modes of remote control 24, touch screen, and button to realize the roller groove grinding operation. In order to ensure safe and reliable operation, 6 proximity switches are installed in the four directions of feed, retract, left and right of the roller groover for stroke control and automatic control during operation.

[0057] Since the stepper motor has the advantages of simple control and convenient speed regulation, the present invention has developed a method of driving the lead screw to rotate by a stepper motor and a belt, and the lead screw drives the wire clamping unit 1 (such as a welding clamp) to move along the X-axis direction or the Y-axis direction, and adopts PLC to design the running track of the welding clamp, so as to realize the automatic feeding and movement of the welding clamp holding the welding wire during the welding process, and realize the automatic welding of the roller. The intelligent roller groove grinding machine described in the present invention can be modified according to production requirements to meet the needs of different similar equipment of various enterprises. The intelligent roller groove grinding machine described in the present invention has a simple structure and is easy to operate, which realizes the automatic welding operation of the roller, improves the operation efficiency, and reduces safety hazards.

[0058] According to the operation property of roller groove grinding, the present invention develops a control device capable of realizing automatic welding function, thereby replacing the manual online groove grinding operation.

[0059] The implementation process of the intelligent roller groove grinding device of the present invention is introduced below. The design method of the intelligent roller groove grinding device includes the following steps:

[0060] S1. Design electrical schematics: Design to meet on-site requirements such as Figure 2 The control principle diagram of the intelligent roller groove grinding device shown in FIG. Figure 3 The electrical control system block diagram is shown.

[0061] S2. Prepare relevant materials: electrical materials: Weiluntong TK6051IP touch screen, FX2nPLC, remote control 24, AC / DC24V power supply 25, two stepper motors and controllers each, buttons with indicator lights, conversion switches, wiring terminals, distribution boxes and other components.

[0062] S3. According to the schematic diagram, assemble the electrical components in the control box, such as Figure 4 shown.

[0063] S4. Programming and debugging are performed on the touch screen and PLC respectively. The program written by the invention fully complies with and meets the following operating requirements. The program of the welding clamp operation trajectory is designed by PLC to realize automatic feeding and movement of the welding clamp during the welding process.

[0064] S5. Material production, assembly and debugging of mechanical transmission systems, such as Figure 1 Shown is the block diagram of the mechanical transmission system of the intelligent roller groove grinding device.

[0065] The operating method of the intelligent roller groove grinding device of the present invention comprises the following steps:

[0066] S1. Clamp the welding wire on the welding wire clamping unit 1. In this embodiment, the welding wire clamping unit 1 is a wire clamp, and the welding wire is a steel wire.

[0067] S2. Switch SA1 to the "on" position and set the parameters on the touch screen.

[0068] S3. Use a button or remote controller 24 to adjust the wire welding start point position.

[0069] S4, start the drive roller control inverter to rotate the roller.

[0070] S5. Switch SA2 to the "flat roller" position.

[0071] S6. Use the touch screen or remote control 24 to start the slotting machine, and the M2 motor starts slotting at the "feed frequency". After reaching the "slotting time", the M1 motor moves at the "walking frequency" and runs the "walking step". M1 stops, the "slotting display" counts 1 circle, and the next circle of slotting begins. After reaching the "allowed number of circles", the slotting machine pauses, and after the "pause time", the slotting machine automatically starts.

[0072] S7, the steel wire is consumed to a shorter length, the advance / retract mechanism baffle moves to the SQ3 position, and the advance / retract mechanism automatically returns to the SQ4 position at a high frequency and stops.

[0073] S8. After changing the steel wire, enter the grooving operation state again.

[0074] The functions of the buttons of the intelligent roller groove grinding device of the present invention are introduced as follows:

[0075] (1) SA1: Power 25 on / off, SA2: Flat roller, manual, concave roller grooving mode selection. When changing the welding wire, set SA2 to "manual" and disconnect the welding power 25.

[0076] (2) The four buttons of the distribution box door, namely, feed, exit, left and right, correspond to the 243, 4, 5 and 6 keys of the remote control, which can realize the manual feed, exit, left and right control of the welding wire, and the corresponding indicator lights are on at the same time.

[0077] (3) Press the touch screen "Left Start" or the remote control 24 "1" button to run to the left, and press again to stop. Press the touch screen "Right Start" or the remote control 24 "2" button to run to the right, and press again to stop.

[0078] The parameter settings on the touch screen are as follows:

[0079] (1) Grinding groove display: only display function, cannot be changed, other functions can be changed.

[0080] (2) Travel frequency: The speed setting of the left and right displacement of the slotting machine.

[0081] (3) Walking step: The distance between each circle of welding points, generally set to 15mm.

[0082] (4) Feed frequency: The speed at which the wire moves forward. If it is set too high, the wire will easily pile up and arc will not form. It should be set at around 1100-1200.

[0083] (5) Groove grinding time: set it to twice the time it takes for the roller to make one revolution.

[0084] (6) Allowable number of turns: To prevent the wire and welding clamp from overheating during operation, the slotting machine automatically pauses the parameter setting.

[0085] (7) Pause time: The cooling time of the slotting machine wire and clamps. When the time is up, it will start automatically.

[0086] The intelligent roller groove grinding device of the present invention has the following characteristics:

[0087] First, easy operation. The electrical control system is designed with three operation modes: remote controller 24, touch screen 22, and button. All of them can realize automatic and manual operation control of the intelligent groove grinding machine.

[0088] Second, the parameter setting is flexible and convenient. By clicking the dialog box on the touch screen 22 and changing the data parameters on the touch screen 22, the running speed of the drive motor can be controlled and the groove grinding time can be set.

[0089] Third, with perfect protection function, six proximity switches are installed in the four positions of feed, retract, left and right of the slot grinder to control the stroke of the system and the automatic control during operation.

[0090] Fourth, the automation of the roller groove grinding process is realized, which reduces the labor intensity of operators and avoids the occurrence of accidental injuries during the operation.

[0091] The mechanical transmission process of the intelligent roller groove grinding device of the present invention is as follows:

[0092] The first stepper motor 5 starts to rotate by controlling the transmission signal through the PLC controller 19, driving the first lead screw 3 to rotate, driving the first slider 2 to move in the X direction; the second stepper motor 12 starts to rotate by transmitting the signal through the PLC controller 19, driving the second lead screw 9 to rotate, driving the second slider 7 to move in the Y direction; through the movement of the first slider 2 and the second slider 7, the movement of the welding wire clamping unit 1 is controlled to realize the control and adjustment of the welding wire trajectory. The first roller 17 and the second roller 14 are fixed on the support 15, and the roller 18 is placed above the first roller 17 and the second roller 14. The AC motor 16 drives the first roller 17 and the second roller 14 to rotate, thereby driving the roller to rotate.

[0093] The intelligent roller groove grinding device described in the present invention replaces manual work with machine operation, realizes safe offline groove making, reduces the labor intensity of workers, and avoids the occurrence of accidental injuries during operation. In the past, offline groove making required the cooperation of two people, but now it can be easily completed by one person, which can save 120,000 yuan in human resource costs each year and significantly improve work efficiency. It can save 80 hours of production preparation time for the two workshops each year and increase annual production capacity by 14,000 tons. Calculated at a benefit of 200 yuan per ton of steel, the annual benefit that can be created for the factory is: 14,000 tons X 200 yuan / ton = 2,800,000 yuan.

[0094] The above-described embodiments are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should all fall within the scope of protection determined by the claims of the present invention.

Claims

1. An intelligent roller groove grinding device, characterized in that: The device comprises: a roll welding mechanism and a roll supporting mechanism; The roller welding mechanism comprises a base (11), a moving unit installed above the base (11), and a welding wire clamping unit (1) installed on the moving unit; The moving unit comprises a first moving unit for driving the welding wire clamping unit (1) to move along the X-axis direction and a second moving unit for driving the welding wire clamping unit (1) to move along the Y-axis direction; the first moving unit comprises a first lead screw (3), a first slider (2) connected to the first lead screw (3), and a first stepper motor (5) for driving the first lead screw (3) to rotate; the second moving unit comprises a second lead screw (9), a second slider (7) connected to the second lead screw (9), and a second stepper motor (12) for driving the second lead screw (9) to rotate; The roller support mechanism comprises a roller unit and an AC motor (16) for driving the roller unit to rotate.

2. The intelligent roller groove grinding device according to claim 1, characterized in that: The device further comprises a PLC controller (19); the output end of the PLC controller (19) is respectively connected to the control ends of the first stepper motor (5), the second stepper motor (12), and the AC motor (16); the PLC controller (19) is respectively connected to the first stepper motor (5), the second stepper motor (12), and the AC motor (16) via a drag chain cable (6); the first stepper motor (5), the second stepper motor (12), and the AC motor (16) are connected to a power source (25) via the drag chain cable (6).

3. The intelligent roller groove grinding device according to claim 1, characterized in that: The second lead screw (9) is mounted on the top of the base (11), and two first bearing seats (4) are mounted on the top of the base (11), and a first bearing is mounted in the first bearing seat (4); the two ends of the screw of the second lead screw (9) are respectively mounted in the first bearings in the two first bearing seats (4); and a plurality of limit blocks (10) are mounted on the base (11).

4. The intelligent roller groove grinding device according to claim 1, characterized in that: A second slide rail (13) is also installed on the top of the base (11); the second slide rail (13) passes through the second slider (7); there are two second slide rails (13), and the two second slide rails (13) are respectively located on the left and right sides of the second lead screw (9).

5. The intelligent roller groove grinding device according to claim 1, characterized in that: The first movable unit is mounted above the second movable unit; the first lead screw (3) is mounted on the top of the second slider (7); two second bearing seats are mounted on the top of the second slider (7), and second bearings are mounted in the second bearing seats; the two ends of the screw of the first lead screw (3) are respectively mounted in the second bearings of the two second bearing seats; the welding wire clamping unit (1) is mounted above the first slider (2).

6. The intelligent roller groove grinding device according to claim 1, characterized in that: A fixing seat (8) is sleeved on the second slide rail (13); the fixing seat (8) and the second slide rail (13) are clearance-matched; and the second sliding block (13) is fixedly connected to the fixing seat (8).

7. The intelligent roller groove grinding device according to claim 1, characterized in that: The roller table unit comprises a first roller table (17) and a second roller table (14) arranged side by side; the first roller table (17) and the second roller table (14) are respectively installed on a support (15); the first roller table (17) is driven to rotate by the AC motor (16), and the second roller table (14) is driven to rotate by the first roller table (17); the AC motor (16) is a three-phase AC motor.

8. The intelligent roller groove grinding device according to claim 1, characterized in that: The first lead screw (3) comprises a first screw and a first nut sleeved on the first screw and threadedly connected to the first screw; the first slider (2) is fixedly connected to the first nut; the output end of the first stepper motor (5) is connected to the first screw, or the output end of the first stepper motor (5) is coupled to the first screw through a first belt; The second lead screw (9) comprises a second screw rod and a second nut sleeved on the second screw rod and threadedly connected to the second screw rod; the second slider (7) is fixedly connected to the second nut; the output end of the second stepper motor (12) is connected to the second screw rod, or the output end of the second stepper motor (12) is coupled to the second screw rod through a second belt.

9. The intelligent roller groove grinding device according to claim 1, characterized in that: The device also includes a first stepper motor driver (20), a second stepper motor driver (21), a remote controller (24), a remote control receiver (23), a display screen (22) and a power supply (25); The power supply (25) is used to supply power to the PLC controller (19), the first stepper motor driver (20), the second stepper motor driver (21), the remote control receiver (23), and the display screen (22); The input end of the first stepper motor driver (20) is connected to the output end of the PLC controller (19), and the output end of the first stepper motor driver (20) is connected to the control end of the first stepper motor (5); the input end of the second stepper motor driver (21) is connected to the output end of the PLC controller (19), and the output end of the second stepper motor driver (21) is connected to the control end of the second stepper motor (12); the first stepper motor driver (20) controls the movement of the first stepper motor (5) through a control line, and the second stepper motor driver (21) controls the movement of the second stepper motor (12) through a control line; The PLC controller (19) is connected to the remote control receiver (19) via a communication line; The remote control receiver (19) is wirelessly connected to the remote control (24); The PLC controller (19) is connected to the display screen (22) via a data bus; The PLC controller (19) adopts a programmable logic controller FX2nPLC, and the touch screen (22) adopts a Weiluntong touch screen TK6051IP.

10. The control method of the intelligent roller groove grinding device according to any one of claims 1 to 9, characterized in that: The method comprises the following steps: The PLC controller (19) sends a control signal to control the first stepper motor (5) to rotate, the first stepper motor (5) drives the first lead screw (3) to rotate, and the first lead screw (3) drives the first slider (2) to move along the X-axis direction; the PLC controller (19) sends a control signal to control the second stepper motor (12) to rotate, the second stepper motor (12) drives the second lead screw (9) to rotate, and the second lead screw (9) drives the second slider (7) to move along the Y-axis direction; by controlling the movement of the first slider (2) and the second slider (7), the welding wire clamping unit (1) is controlled to move along the X-axis direction or the Y-axis direction, so as to adjust the welding wire trajectory.

Images