Servo press control system based on CODESYS platform and control method thereof

Abstract

The invention relates to the technical field of industrial automation control, in particular to a servo press control system based on a CODESYS platform and a control method of the servo press control system. The system comprises a control system overall architecture, a core control algorithm, a man-machine interaction interface design and a safety protection mechanism. According to the system, by integrating powerful functions of a CODESYS platform, efficient and accurate control over the servo press is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial automation control, and in particular to a servo press control system and a control method thereof based on a CODESYS platform. Background Art

[0002] Servo presses play a vital role in modern industrial production. Traditional press control systems have many problems, such as low control accuracy, slow response speed, and difficulty in achieving complex pressure curve control. With the development of industrial automation, the performance requirements for press control systems are increasing.

[0003] As a powerful industrial automation programming and development platform, CODESYS platform provides a new way to optimize the design of servo press control system. However, the current design of servo press control system based on CODESYS platform still has some shortcomings, which cannot give full play to the advantages of the platform and meet the needs of high-precision production. Summary of the invention

[0004] The purpose of the present invention is to provide a servo press control system and a control method thereof based on the CODESYS platform to solve the problems existing in the prior art, improve the control accuracy and stability of the servo press, and reduce programming difficulty and maintenance cost.

[0005] To achieve the above objectives, the present invention discloses a servo press control system and a control method thereof based on the CODESYS platform, including the overall architecture of the control system, a core control algorithm, a human-computer interaction interface design, and a safety protection mechanism.

[0006] As a further design of this solution, the overall architecture of the control system includes hardware architecture and software architecture.

[0007] The hardware architecture is composed of key components such as the host computer, CODESYS runtime system, servo drive, servo motor, pressure sensor, etc.

[0008] 1) The host computer communicates with the CODESYS runtime system via Ethernet. As the monitoring and management center of the system, it has powerful computing and data processing capabilities, supports the CODESYS development environment, and is responsible for the system's parameter configuration and status monitoring.

[0009] 2) The CODESYS runtime system serves as the core control hub and the core control unit. It is connected to the servo drive through a high-speed field bus (such as EtherCAT), receives host computer instructions and converts them into servo drive control signals, and receives and processes feedback signals from sensors.

[0010] 3) The servo drive is connected to the servo motor. The servo drive accurately controls the servo motor according to the instructions of the CODESYS runtime system to provide the power required for the movement of the press slide. The selected servo motor is customized according to the working requirements of the press (such as maximum pressure, speed range, etc.).

[0011] 4) The pressure sensor is installed at the key stress-bearing parts of the press to monitor the pressure changes in real time, and convert the pressure signal into an electrical signal and feed it back to the CODESYS runtime system to provide accurate feedback for pressure control.

[0012] The software architecture adopts a modular design on the CODESYS platform, and each module works together to achieve precise control of the servo press.

[0013] 1) Parameter setting module: This module is used to store and manage the working parameters of the press, including the pressure target value, travel range, speed parameters and working mode (such as constant pressure mode, gradual pressure mode, etc.). The accuracy of parameter setting is determined according to the design specifications of the press. For example, the setting accuracy of the pressure target value can reach ±0.1kN, the travel range can be accurate to ±1mm, and the speed parameter can be set within the range of 1-50mm / s with an accuracy of 0.1mm / s.

[0014] 2) Motion control module: Generate the motion trajectory of the servo motor according to the working parameters set by the parameter setting module to accurately control the movement of the press slide. The S-shaped velocity curve motion control algorithm ensures that the slide moves smoothly and accurately, and works in conjunction with the servo driver to ensure the accuracy of instruction transmission. Assuming that the S-shaped velocity curve consists of a jerk segment, a uniform acceleration segment, and a deceleration segment, it can be described by the following formula:

[0015] Jerk section:

[0016]

[0017] Where v0 is the initial velocity, a0 is the initial acceleration, and j is the jerk;

[0018] Uniform acceleration section:

[0019] v(t)=v0+at

[0020] Where a is a constant acceleration;

[0021] Deceleration stage:

[0022]

[0023] where v max is the maximum speed, t max is the time to reach maximum speed.

[0024] Improvement: The introduction of jerk j makes the velocity curve smoother and reduces the impact and vibration of the mechanical system. By adjusting the parameters of initial acceleration a0, constant acceleration a and jerk j, the shape and performance of the velocity curve can be optimized to meet different motion control requirements.

[0025] 3) Pressure control module: Combined with the feedback signal of the pressure sensor, the fuzzy adaptive PID control algorithm is used to adjust the servo motor output in real time to achieve high-precision pressure control. The algorithm dynamically adjusts the PID parameters according to the pressure deviation and change rate to optimize the system response speed and stability.

[0026] 4) Data acquisition and processing module: collects various data during the operation of the press (such as pressure, position, speed, etc.), and performs filtering to remove noise interference (such as mean filtering algorithm). The processed data is statistically analyzed and stored in the local storage device for subsequent query, analysis and fault diagnosis.

[0027] 5) Fault diagnosis and alarm module: real-time monitoring of system operation status, analysis of key parameters (such as motor current, temperature, pressure sensor signals, etc.), timely detection of abnormalities and location of faults. When a fault occurs, the system displays alarm information through the human-computer interaction interface, including fault type and location information.

[0028] At the same time, the alarm information is sent to the remote monitoring system to facilitate timely processing by maintenance personnel.

[0029] As a further design of this solution, the core control algorithm is mainly the fuzzy adaptive PID algorithm. In this control system, by optimizing fuzzy rules, membership functions and fuzzy reasoning methods, and dynamically adjusting PID parameters, the accuracy and adaptability of the control system can be significantly improved, and complex nonlinear problems that traditional PID control algorithms cannot cope with can be solved. The basic principle is to use the pressure deviation e (the difference between the target pressure and the actual pressure) and the deviation change rate ec as input variables, and adjust the three parameters K of the PID controller through fuzzy reasoning. p (proportional coefficient), K i (integral coefficient) and K d (differential coefficient).

[0030] 1) Fuzzification process: First, determine the fuzzy sets and membership functions of the input variables e and ec. The fuzzy set of the pressure deviation e can be set to {negative large (NB), zero (Z), positive large (PB)}, and the fuzzy set of the deviation change rate ec is set to be the same as e.

[0031] Membership function of zero (Z): where e z is the width of the error range for the zero set, e trIt is the transition error value from the "zero" set to other sets.

[0032]

[0033] The membership function of negative big (NB) and positive big (PB) (taking NB as an example, PB is similar but in the opposite direction): where e max is the maximum error value of the NB set, e tr It is the transition error value from the NB set to other sets.

[0034]

[0035] 2) Fuzzy rule formulation: According to expert experience and actual debugging results, a fuzzy rule table is formulated. For example, "If the pressure deviation is negative large (NB) and the deviation change rate is negative large (NB), then increase the proportional coefficient K p ","If the pressure deviation is zero (Z) and the deviation change rate is zero (Z), then keep the integral coefficient K i and the differential coefficient K d Such rules flexibly adjust PID parameters according to different combinations of deviation and change rate to optimize pressure control performance.

[0036] 3) Defuzzification: The fuzzy quantity obtained through fuzzy reasoning needs to be converted into accurate PID parameter adjustment quantity. Common defuzzification methods include centroid method, maximum membership method, etc. This system uses the centroid method to convert the fuzzy reasoning result into a specific K p , K i , K d The adjusted PID parameters are then applied to the controller to achieve real-time control of the pressure.

[0037] 4) Dynamically adjust PID parameters: Among them, ΔK p (t),ΔK i (t),ΔK d (t) is the adjustment value calculated by the fuzzy control system, K p (0),K i (0),K d (0) is the initial setting value of the PID controller.

[0038] K p (t) = K p (0)+ΔK p (t)

[0039] K i (t) = K i (0)+ΔK i (t)

[0040] Kd (t) = K d (0)+ΔK d (t)

[0041] In application, the design and adjustment of the fuzzy control system is an iterative process, which requires continuous optimization and debugging according to the process requirements of the servo press.

[0042] As a further design of this solution, the human-computer interaction interface is designed with information display function, parameter input function and fault display function.

[0043] 1) Information display function: The interface clearly and in real time displays the key information of the press, including pressure value, slider position and running speed, etc. The pressure value is displayed in digital form, and a bar graph is provided to show the pressure change trend; the slider position is indicated by a dynamic model and numerical value; the running speed is displayed in digital form and on a speed dial, so that the operator can instantly understand the equipment status.

[0044] 2) Parameter input function: Operators can easily input and modify working parameters through the touch screen. The interface has a dedicated parameter input area to support the setting of pressure target value, travel range, speed and other parameters. The value is entered through the numeric keypad, and the working mode is selected through the selection button (such as constant pressure mode, gradual pressure mode). After the input parameters are checked for legality, they are stored in the parameter setting module to ensure the validity of the parameters.

[0045] 3) Fault display function: When a system fails, the interface will use red flashing text and alarm icons to highlight the fault type and location. Fault information includes the fault type (such as motor failure, sensor failure, communication failure, etc.) and specific location (such as motor number, sensor number, etc.), helping maintenance personnel to quickly diagnose and repair. At the same time, it provides troubleshooting suggestions or guides to detailed fault reports.

[0046] Facilitates subsequent processing.

[0047] As a further design of this solution, the security protection mechanism includes hardware security protection measures and software security protection measures.

[0048] 1) Hardware safety protection measures: Multiple limit switches are installed on the stroke path of the press slide, including upper limit switch, lower limit switch and intermediate safety limit switch. When the slide approaches or exceeds the safety stroke, the limit switch triggers a signal to immediately stop the servo motor to avoid over-travel damage. Emergency stop buttons are installed on the operation panel and surrounding areas to ensure that the power supply can be quickly cut off and the equipment can be stopped immediately in an emergency (such as a fault or abnormality). The emergency stop button adopts a normally closed contact design to ensure that the circuit is conductive under normal circumstances. Once the button is pressed, the circuit is disconnected to achieve a quick shutdown.

[0049] 2) Software security protection measures: At the software level, real-time monitoring of key system parameters, such as motor current, temperature, pressure sensor signals, etc. By setting reasonable safety thresholds, when the parameters exceed the safety thresholds, the protection program is automatically triggered. For pressure sensor signals, when the signal value exceeds the normal pressure range or there is signal loss, abnormal fluctuations, etc., the corresponding protection measures will also be triggered; the system is set with a password protection function, and only operators who enter the correct user name and password can enter the parameter setting interface to modify parameters.

[0050] The present invention also provides a servo press control method based on the CODESYS platform, the method comprising the following steps:

[0051] Step 1: Demand analysis: Communicate with production and users to clarify the application scenarios, working modes (constant pressure, variable pressure, pressure maintenance, etc.) and related parameters of the press; determine the maximum pressure, control accuracy, stroke range, speed range, repeat positioning accuracy and production efficiency-related indicators based on process requirements; determine safety requirements according to industry standards and environment, including emergency stop, stroke limit, electrical safety, fault diagnosis and alarm requirements.

[0052] Step 2: Hardware design: Calculate the torque based on the maximum pressure and mechanical transmission structure, select the appropriate model based on the speed range and leave a safety margin; select a matching driver based on the servo motor, considering the power capacity and supported control and communication modes; select the sensor according to the pressure range and accuracy requirements, considering linearity, repeatability and output signal type; select a host computer and human-machine interface (HMI) that meet the CODESYS operating requirements, and build a hardware connection architecture.

[0053] Step 3: Software design: Create a project in CODESYS, select the corresponding template and runtime system version, and configure communication parameters; create function blocks to store and manage working parameters, design input interfaces, parameter checking and storage functions; design motion control algorithms based on kinematic principles and parameters, and use CODESYS motion control library functions to implement motor control; design fuzzy adaptive PID algorithms, including determining fuzzy sets, membership functions, and fuzzy rules to implement algorithm programming; configure data acquisition functions, filter, analyze and store acquired data; establish fault diagnosis logic, monitor key parameters and status, and design alarm and fault handling mechanisms; design HMI interface layout, including displaying working status, parameter input area and fault display alarm interface.

[0054] Step 4: System integration and debugging: Download the software to the CODESYS runtime system, check the hardware identification and initialization; debug the parameter setting, motion control, pressure control, data acquisition and processing, fault diagnosis and alarm modules separately; debug jointly under load conditions, optimize the system according to the results, and check the long-term operation reliability of the system.

[0055] Step 5: System testing and verification: Use professional equipment to test the performance of the press under different conditions and compare the results with the design requirements; test the safety protection mechanism, including emergency stop, travel limit and electrical safety; conduct small batch production tests on the production line and adjust and optimize the system based on feedback.

[0056] Beneficial effects of the present invention:

[0057] 1. Improve control accuracy: Use advanced control algorithms to achieve precise control of the servo press and improve product quality.

[0058] 2. Enhance system adaptability and flexibility: Based on the open platform of CODESYS, it supports multiple programming languages ​​and multiple working modes, which facilitates system expansion, maintenance and adaptation to changes in different working conditions.

[0059] 3. Improve system reliability: Integrate comprehensive hardware security protection measures and reliable software security protection mechanisms, and reduce failure rates and improve production efficiency through fault diagnosis and early warning modules.

[0060] 4. Improve operational convenience and monitoring capabilities: Friendly human-computer interaction interface and complete data collection and processing functions provide strong support for optimizing production processes and improving equipment maintenance efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 Schematic diagram of the overall system architecture of the present invention.

[0062] Figure 2 The present invention is a flow chart of the method. DETAILED DESCRIPTION

[0063] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. It should be noted that the words "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to directions in the accompanying drawings, and the words "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0064] like Figure 1As shown, this embodiment provides a complex structure sand mold water jet and air knife composite processing system, which mainly includes: control system overall architecture, core control algorithm, human-computer interaction interface design, and safety protection mechanism.

[0065] The overall architecture of the control system includes hardware architecture and software architecture.

[0066] The hardware architecture is composed of key components such as the host computer, CODESYS runtime system, servo drive, servo motor, pressure sensor, etc.

[0067] 1) The host computer communicates with the CODESYS runtime system via Ethernet. As the monitoring and management center of the system, it has powerful computing and data processing capabilities, supports the CODESYS development environment, and is responsible for the system's parameter configuration and status monitoring.

[0068] 2) The CODESYS runtime system serves as the core control hub and the core control unit. It is connected to the servo drive through a high-speed field bus (such as EtherCAT), receives host computer instructions and converts them into servo drive control signals, and receives and processes feedback signals from sensors.

[0069] 3) The servo drive is connected to the servo motor. The servo drive accurately controls the servo motor according to the instructions of the CODESYS runtime system to provide the power required for the movement of the press slide. The selected servo motor is customized according to the working requirements of the press (such as maximum pressure, speed range, etc.).

[0070] 4) The pressure sensor is installed at the key stress-bearing parts of the press to monitor the pressure changes in real time, and convert the pressure signal into an electrical signal and feed it back to the CODESYS runtime system to provide accurate feedback for pressure control.

[0071] The software architecture adopts a modular design on the CODESYS platform, and each module works together to achieve precise control of the servo press.

[0072] 1) Parameter setting module: This module is used to store and manage the working parameters of the press, including the pressure target value, travel range, speed parameters and working mode (such as constant pressure mode, gradual pressure mode, etc.). The accuracy of parameter setting is determined according to the design specifications of the press. For example, the setting accuracy of the pressure target value can reach ±0.1kN, the travel range can be accurate to ±1mm, and the speed parameter can be set within the range of 1-50mm / s with an accuracy of 0.1mm / s.

[0073] 2) Motion control module: The motion control module generates the motion trajectory of the servo motor according to the parameters set by the parameter setting module, and accurately controls the movement of the press slide. It uses advanced motion control algorithms to convert the travel range and speed parameters into the speed and angle instructions of the servo motor. For example,

[0074] In the constant speed motion stage, the motor speed and running time are calculated according to the set speed and stroke;

[0075] In the variable speed movement stage, the complex speed planning algorithm S-shaped speed curve planning ensures the smoothness and accuracy of the slider movement. At the same time, the module works closely with the servo drive, and sends instructions to the servo drive accurately through the communication function of the CODESYS platform to achieve precise control of the motor.

[0076] 3) Pressure control module: The pressure control module is one of the cores of this control system. It combines the feedback signal of the pressure sensor and adjusts the output of the servo motor in real time by integrating the fuzzy adaptive PID control algorithm, thereby achieving high-precision pressure control. During the pressure control process, the fuzzy adaptive PID algorithm adjusts the PID parameters in real time according to the pressure deviation and the deviation change rate. For example, when the pressure deviation is large and the deviation change rate is fast, the proportional coefficient is appropriately increased to speed up the response speed of the system; when the pressure is close to the target value and the deviation change rate is small, the proportional coefficient is reduced and the integral and differential coefficients are appropriately adjusted to improve the stability of the system.

[0077] 4) Data acquisition and processing module: This module is responsible for collecting various data during the operation of the press, including pressure, position, speed, etc. The collected data comes from the pressure sensor, motor status information fed back by the servo drive, etc. For the collected data, filtering is first performed to remove noise interference. For example, the mean filtering algorithm is used to average multiple consecutive sampling values, which can effectively smooth data fluctuations caused by the sensor's own noise or external interference. Then the filtered data is analyzed to calculate statistical information such as pressure peak, average pressure, travel time, etc., and the data is stored in a local storage device (such as a hard disk or an external database). The stored data format and structure are carefully designed to facilitate subsequent data query, analysis, and fault diagnosis.

[0078] 5) Fault diagnosis and alarm module: This module monitors the system operation status in real time, and promptly detects possible abnormal conditions in the system by monitoring and analyzing key parameters (such as motor current, temperature, pressure sensor signal, system communication status, etc.). When an abnormality is detected, the cause of the fault is quickly located and an alarm message is issued. For example, when the servo motor current exceeds a certain proportion of the rated current, it is judged that the motor may be overloaded; when the pressure sensor signal exceeds the normal pressure range or the signal is lost, it is judged that the pressure detection link has a fault. The alarm information is displayed to the operator in a striking manner through the human-computer interaction interface, including the fault type (such as motor overload, sensor failure, communication failure, etc.) and location information (such as which motor, which sensor or which communication node has a problem). At the same time, the alarm information can be sent to the remote monitoring system (if necessary) so that maintenance personnel can obtain fault information in time and take corresponding maintenance measures.

[0079] The core control algorithm is mainly the fuzzy adaptive PID algorithm. In this control system, the fuzzy adaptive PID algorithm plays a key role in pressure control. Its basic principle is to use the pressure deviation e (the difference between the target pressure and the actual pressure) and the deviation change rate ec as input variables, and adjust the three parameters K of the PID controller through fuzzy reasoning. p (proportional coefficient), K i (integral coefficient) and K d (differential coefficient).

[0080] 1) Fuzzification process: First, determine the fuzzy sets and membership functions of the input variables e and ec. The fuzzy set of pressure deviation can be set to {negative large (NB), zero (Z), positive large (PB)}, and its membership function can use a triangular or trapezoidal function. The value range of each fuzzy set is determined according to the pressure range and control accuracy requirements of the press. For example, for a press with a pressure range of 0-100kN, negative large (NB) can be defined as a deviation less than -10kN, and positive large (PB) can be defined as a deviation greater than 10kN. The fuzzy set and membership function of the deviation change rate ec are also defined in a similar way.

[0081] 2) Fuzzy rule formulation: According to expert experience and actual debugging results, a fuzzy rule table is formulated. For example, "If the pressure deviation is negative (PB) and the deviation change rate is negative (PB), then increase the proportional coefficient K p ","If the pressure deviation is zero (Z) and the deviation change rate is zero (Z), then keep the integral coefficient K i and the differential coefficient K d These rules reflect how to adjust PID parameters to achieve better pressure control effect under different pressure deviations and deviation change rates.

[0082] 3) Defuzzification: The fuzzy quantity obtained through fuzzy reasoning needs to be converted into accurate PID parameter adjustment quantity. Common defuzzification methods include centroid method, maximum membership method, etc. This system uses the centroid method to convert the fuzzy reasoning result into a specific K p , K i , K d The adjusted PID parameters are then applied to the controller to achieve real-time control of the pressure.

[0083] The human-computer interaction interface design includes information display function, parameter input function and fault display function.

[0084] 1) Information display function: The current working status of the press is clearly and in real time displayed on the interface, including key information such as pressure value, slider position, and running speed. This information is displayed in the form of numbers, graphics, or charts. For example, the pressure value is displayed in a prominent position in digital form, and the pressure change trend is displayed through a bar chart; the slider position is displayed through a dynamic slider model and position value; the running speed is presented in the form of numbers and a speed dial, which makes it easy for operators to understand the working status of the press at a glance.

[0085] 2) Parameter input function: Operators can easily input and modify working parameters through the touch screen. The human-computer interaction interface provides a special parameter input area, and sets corresponding input boxes and selection buttons for different parameters (such as pressure target value, travel range, speed parameter, working mode, etc.). For example, for the pressure target value, the operator can enter the specific value through the numeric keypad; for the working mode, it can be selected by clicking the corresponding mode button (such as constant pressure mode, gradual pressure mode, etc.). The input parameters are stored in the parameter setting module after the legality check to ensure that the parameters received by the system are reasonable and valid.

[0086] 3) Fault display function: When a system fault occurs, the human-computer interaction interface will indicate the fault type and location in a striking manner. The fault information is displayed in a prominent position on the interface in the form of red flashing text, alarm icons, etc., and the fault type (such as motor fault, sensor fault, communication fault, etc.) and fault location (such as which motor number, sensor number or communication link has a problem) are listed in detail to help maintenance personnel quickly diagnose and repair the problem. In addition, troubleshooting suggestions can be provided or maintenance personnel can be guided to view detailed fault diagnosis reports.

[0087] Security protection mechanisms include hardware security protection measures and software security protection measures.

[0088] 1) Hardware safety protection measures: Multiple limit switches are installed on the stroke path of the press slide to limit the stroke of the slide. These limit switches include upper limit switch, lower limit switch and intermediate safety limit switch. When the slide approaches or exceeds the normal stroke range, the limit switch is activated and sends a signal to the CODESYS runtime system. The system immediately stops the operation of the servo motor to prevent the slide from overtravel accidents and damage to the mechanical structure of the press. For example, the upper limit switch is set slightly below the upper limit position of the slide stroke. When the slide triggers the upper limit switch, it indicates that the slide has approached or exceeded the upper limit of the safe stroke range, and the system responds quickly; install an emergency stop button on the press operation panel and in a conspicuous position around it. When an emergency occurs (such as the operator discovers an abnormality, sudden equipment failure may cause danger, etc.), pressing the emergency stop button can immediately cut off the power supply and stop the entire press. The emergency stop button adopts a normally closed contact design to ensure that the circuit is in a conducting state under normal circumstances. Once the button is pressed, the circuit is disconnected to achieve a fast and reliable emergency stop function.

[0089] 2) Software security protection measures: At the software level, real-time monitoring of key system parameters, such as motor current, temperature, pressure sensor signals, etc. By setting reasonable safety thresholds, the protection program is automatically triggered when the parameters exceed the safety thresholds. For example, when the current of the servo motor exceeds 120% of its rated current, the software determines that the motor may be in an overloaded state, immediately stops the press action, and sends an alarm signal. For the pressure sensor signal, when the signal value exceeds the normal pressure range or there is signal loss, abnormal fluctuations, etc., the corresponding protection measures will also be triggered to ensure that the press operates within a safe parameter range; to prevent unauthorized personnel from modifying system parameters, the system has set a password protection function. Only operators who enter the correct user name and password can enter the parameter setting interface to modify the parameters. The password is encrypted and stored to improve the security of the system and prevent equipment failures or safety accidents caused by malicious modification of parameters.

[0090] like Figure 2 As shown, this embodiment provides a servo press control method based on the CODESYS platform, and the method includes the following steps:

[0091] Step 1: Demand analysis: Communicate with production and users to clarify the application scenarios, working modes (constant pressure, variable pressure, pressure maintenance, etc.) and related parameters of the press; determine the maximum pressure, control accuracy, stroke range, speed range, repeat positioning accuracy and production efficiency-related indicators based on process requirements; determine safety requirements according to industry standards and environment, including emergency stop, stroke limit, electrical safety, fault diagnosis and alarm requirements.

[0092] Step 2: Hardware design: Calculate the torque based on the maximum pressure and mechanical transmission structure, select the appropriate model based on the speed range and leave a safety margin; select a matching driver based on the servo motor, considering the power capacity and supported control and communication modes; select the sensor according to the pressure range and accuracy requirements, considering linearity, repeatability and output signal type; select a host computer and human-machine interface (HMI) that meet the CODESYS operating requirements, and build a hardware connection architecture.

[0093] Step 3: Software design: Create a project in CODESYS, select the corresponding template and runtime system version, and configure communication parameters; create function blocks to store and manage working parameters, design input interfaces, parameter checking and storage functions; design motion control algorithms based on kinematic principles and parameters, and use CODESYS motion control library functions to implement motor control; design fuzzy adaptive PID algorithms, including determining fuzzy sets, membership functions, and fuzzy rules to implement algorithm programming; configure data acquisition functions, filter, analyze and store acquired data; establish fault diagnosis logic, monitor key parameters and status, and design alarm and fault handling mechanisms; design HMI interface layout, including displaying working status, parameter input area and fault display alarm interface.

[0094] Step 4: System integration and debugging: Download the software to the CODESYS runtime system, check the hardware identification and initialization; debug the parameter setting, motion control, pressure control, data acquisition and processing, fault diagnosis and alarm modules separately; debug jointly under load conditions, optimize the system according to the results, and check the long-term operation reliability of the system.

[0095] Step 5: System testing and verification: Use professional equipment to test the performance of the press under different conditions and compare the results with the design requirements; test the safety protection mechanism, including emergency stop, travel limit and electrical safety; conduct small batch production tests on the production line and adjust and optimize the system based on feedback.

[0096] The technical means disclosed in the scheme of the present invention are not limited to the technical means disclosed in the above-mentioned implementation mode, but also include technical schemes composed of any combination of the above technical features.

Claims

1. The servo press control system based on CODESYS platform is characterized by: It includes the overall architecture of the control system, core control algorithms, human-computer interaction interface design and safety protection mechanisms.

2. The servo press control system based on the CODESYS platform according to claim 1 is characterized in that: The overall architecture of the control system includes hardware architecture and software architecture. The hardware architecture consists of a host computer, a CODESYS runtime system, a servo driver, a servo motor and a pressure sensor. The software architecture adopts a modular design based on the CODESYS platform, including a parameter setting module, a motion control module, a pressure control module, a data acquisition and processing module, and a fault diagnosis and alarm module to ensure efficient integration and flexible configuration of the system.

3. The servo press control system based on the CODESYS platform according to claim 2 is characterized in that: The software architecture adopts an S-shaped velocity curve as its core motion control algorithm. By introducing jerk, that is, the rate of change of acceleration, the velocity curve is further optimized, making the acceleration and deceleration process smoother.

4. The servo press control system based on the CODESYS platform according to claim 3 is characterized in that: The core control algorithm adopts fuzzy adaptive PID algorithm, which takes pressure deviation e and deviation change rate ec as input variables, determines the fuzzy set and membership function of the input variables through fuzzification process, and adjusts the PID parameter proportional coefficient K through fuzzy inference rules and centroid method defuzzification. p , integral coefficient K i and the differential coefficient K d .

5. The servo press control system based on the CODESYS platform according to claim 4 is characterized in that: The human-computer interaction interface design has a multifunctional module, including pressure display, operating parameter setting, fault diagnosis and alarm functions, which can display the working status of the press in real time, facilitate the operator to input and modify the working parameters in real time, and prompt faults in time, thereby optimizing the operating experience and improving production efficiency.

6. The servo press control system based on the CODESYS platform according to claim 5 is characterized in that: The safety protection mechanism includes hardware safety protection measures and software safety protection measures. The hardware safety protection measures include multiple limit switches and emergency stop buttons; the software safety protection measures include real-time parameter monitoring, fault warning, protection program and password protection functions to ensure the safety and stability of the system and prevent misoperation and fault expansion.

7. The servo press control method based on CODESYS platform is characterized in that: The control system according to any one of claims 1 to 5 comprises the following steps: Step 1: Demand analysis: Communicate with production and users to clarify the application scenarios, working modes and related parameters of the press; determine the maximum pressure, control accuracy, travel range, speed range, repeated positioning accuracy and production efficiency-related indicators based on process requirements; determine safety requirements according to industry standards and environment, including emergency stop, travel limit, electrical safety, fault diagnosis and alarm requirements; Step 2: Hardware design: Calculate the torque based on the maximum pressure and mechanical transmission structure, select the appropriate model based on the speed range and leave a safety margin; select a matching driver based on the servo motor, considering the power capacity and supported control and communication modes; select the sensor according to the pressure range and accuracy requirements, considering linearity, repeatability and output signal type; select the host computer and human-machine interface HMI that meet the CODESYS operation requirements, and build the hardware connection architecture; Step 3: Software design: Create a project in CODESYS, select the corresponding template and runtime system version, and configure communication parameters; create function blocks to store and manage working parameters, design input interfaces, parameter checking and storage functions; design motion control algorithms based on kinematic principles and parameters, and use CODESYS motion control library functions to implement motor control; design fuzzy adaptive PID algorithms, including determining fuzzy sets, membership functions, fuzzy rules, and implementing algorithm programming; configure data acquisition functions, filter, analyze and store acquired data; establish fault diagnosis logic, monitor key parameters and status, and design alarm and fault handling mechanisms; design HMI interface layout, including displaying working status, parameter input area and fault display alarm interface; Step 4: System integration and debugging: Download the software to the CODESYS runtime system and check the hardware identification and initialization; Debug parameter setting, motion control, pressure control, data acquisition and processing, fault diagnosis and alarm modules separately; debug jointly under load conditions, optimize the system according to the results, and check the long-term operation reliability of the system; Step 5: System testing and verification: Use professional equipment to test the performance of the press under different conditions and compare the results with the design requirements; Test safety protection mechanisms, including emergency stop, travel limits and electrical safety; Carry out small batch production tests on the production line and adjust and optimize the system based on the feedback.

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