A control method for power-off and voltage-continuation of automation equipment

Abstract

The present invention discloses a control method for resuming pressurization after power failure in automated equipment. By using a power failure holding relay, the system can remember the pressurization steps after power failure, avoiding data loss due to power failure and ensuring production continuity and data integrity. After a power failure, the system can automatically return to the pressurization steps before the power failure without manual intervention, thereby improving the level of automation and production efficiency. The present invention achieves high-precision power failure continuation, and the user can choose to continue pressurization directly or after resetting. If the equipment loses power during operation, it can automatically resume the steps before the power failure, realizing unattended automated operation after a power failure.

Description

Technical Field

[0001] The present invention relates to the technical field of automation control, and in particular to a control method for power-off and voltage-continuation of automation equipment. Background Art

[0002] Servo motors offer precise positioning and quick response, making them commonly used in automated control equipment. Pulse-type servos offer stable, economical, and reliable performance, and can be positioned using pulses from a PLC or pulse generator. However, the servo drive itself cannot store the distance previously positioned or the current step in the automated operation.

[0003] During PLC program execution, the default data is non-retentive. This means that if the PLC suddenly loses power during operation, the program will be interrupted, and servo operation data, completed steps, and unfinished steps will be lost. When power is restored, the PLC can only be reset and then re-pressed according to the built-in program, resulting in the waste of semi-finished products before the power outage. This impact is particularly serious in multi-part press-fitting applications. If the power is lost midway before the workpiece is fully press-fitted, the PLC will re-press the workpiece when power is restored. This may cause overvoltage, resulting in machine shutdown or damage, and making unattended automated operation impossible after a power outage.

[0004] To solve this problem, relevant technical solutions are already available on the market. For example, a PLC controller creates a REAL variable for a motor that needs to remember its position value after power failure, and sets the REAL variable to a power-off retention variable. However, the basic data type inside the PLC is Integer, which is a 16-bit integer or a 32-bit integer. Converting an integer to a REAL type may result in errors. Secondly, the PLC operates in a cyclical manner. It reads and transfers position information only when the PLC scans the conversion instruction. The stored position information lags behind the actual position information. The faster the servo runs, the greater the error. Therefore, the technical solutions on the market have too large an error and still cannot achieve unattended automated operation after power failure. Therefore, improvements are needed to realize a dark factory, that is, a smart factory, so that all processing, transportation, and testing processes from raw materials to final products can be completed in an environment without human operation. Summary of the Invention

[0005] The present invention aims to solve the defects in the prior art such as failure to realize unattended automatic operation after power failure, and provides a new control method for power failure and voltage continuation of automatic equipment.

[0006] In order to solve the above technical problems, the present invention is achieved through the following technical solutions:

[0007] A method for controlling power-off and voltage-continuation of automated equipment comprises the following steps:

[0008] S1: The device is powered on, the PLC keeps the state of the power-off hold relay unchanged, clears other relays, and then sets the value of the loop run switch to 1. The PLC records the position information of the servo axis in each fixed scan cycle. The PLC determines whether the device is shut down normally based on the state of the power-off hold relay. If so, it proceeds to step S2, otherwise it proceeds to step S3;

[0009] S2: Start the servo origin reset program. After the reset is completed, set the value of the servo reset completion flag to 1 and go to step S4;

[0010] S3: The PLC extracts the position information of the servo axis before power failure. The user chooses to continue press-fitting directly or continue press-fitting after resetting. After press-fitting is completed, the process goes to step S2.

[0011] S4: Check the automatic operation conditions. When the values ​​of the manual start switch, the cycle operation switch, and the servo reset completion switch are 1 and the value of the manual shutdown switch is 0, go to step S5. Otherwise, jump out of the automatic operation cycle and wait for the user to turn off the power.

[0012] S5: Start the press-fitting program, set the value of the cyclic operation switch to 0, use the power-off holding relay to start the servo press-fitting, and after the press-fitting is completed, clear the power-off holding relay, set the value of the cyclic operation switch to 1, and enter step S4.

[0013] The system uses a latching relay to remember the press-fitting steps after a power outage, preventing data loss and ensuring production continuity and data integrity. After a power outage, the system automatically resumes the press-fitting steps immediately prior to the outage, eliminating the need for manual intervention and improving automation and production efficiency. Users can choose to continue press-fitting directly or after a reset, enhancing operational flexibility. The system can determine whether the equipment has shut down normally based on the status of the latching relay and take appropriate action, enhancing system intelligence. Using a latching data register to record servo axis position information reduces errors associated with integer to REAL conversion and improves positioning accuracy. Resuming press-fitting after a reset further minimizes power outage errors and ensures accuracy. In multi-part press-fitting applications, a power outage prevents overvoltage issues caused by the PLC resetting the press-fitting process, protecting both the machine and the workpiece.

[0014] The present invention realizes high-precision power-off continuation pressing through the above design. The user can choose to continue pressing directly or continue pressing after resetting. If the equipment is powered off during operation, it can automatically continue to run the steps before the power outage, realizing unattended automated operation after power outage.

[0015] Preferably, in the above-mentioned control method for power-off and power-on of an automated equipment, in step S5, a power-off holding relay is used to start the servo press-fitting, and after each press-fitting, the value of the power-off holding relay corresponding to the number of the press-fitting step is set to 1.

[0016] A latching relay records every step of the press-fit process, ensuring that the exact steps taken before the power outage can be traced after the power outage. By setting up the relay, the automated equipment can automatically resume the press-fit process after a power outage, eliminating the need for manual intervention, improving automation and enhancing system reliability.

[0017] Preferably, in the above-mentioned control method for power-off and power-on of an automation equipment, in step S1, the PLC determines whether the equipment is shut down normally by the state of the power-off holding relay. When the value of each numbered power-off holding relay is 0, it is judged to be a normal shutdown. When the value of any numbered power-off holding relay is 1, it is judged to be a power-off shutdown.

[0018] The PLC can accurately determine whether the equipment is shutting down normally or due to a power outage. By distinguishing between normal shutdown and power outage shutdown, the system can take different safety measures to prevent the press-fitting program from being started at inappropriate times.

[0019] Preferably, in the above-mentioned control method for continuing pressurization after power failure of an automated device, in step S3, continuing pressurization is to continue to run the pressurization step before power failure of the pressurization program.

[0020] After a power outage, the press-fitting process can be resumed from the previous step, maintaining production continuity and enhancing system stability. The automated recovery process reduces reliance on manual operations.

[0021] Preferably, in the above-mentioned control method for powering on and continuing pressing of automated equipment, in step S3, when the user chooses to continue pressing directly or to continue pressing after resetting, the value of the manual start switch is set to 1.

[0022] By setting a manual start switch, it can be ensured that the press-fitting process will not start until the user has clearly selected it. The user has direct control over the press-fitting process through the manual start switch, which enhances the safety of the operation and can reduce erroneous operations caused by unclear operating intentions.

[0023] Preferably, in the above-mentioned method for controlling power-off and power-on of automated equipment, in step S4, if the user chooses to turn on the manual shutdown switch, the value of the manual shutdown switch is set to 1.

[0024] Users can flexibly choose downtime according to production plans or other situations, which improves production flexibility and enhances users' control over automation equipment.

[0025] Preferably, in the above-mentioned method for controlling power-off and power-on of automation equipment, in step S4, if the value of the servo reset completion flag is 1, the value of the servo reset completion switch is set to 1.

[0026] Waiting until the servo system is fully reset before proceeding to the next step helps avoid system instability caused by an incomplete reset. This ensures the servo system operates in a safe state and reduces potential safety risks caused by an incomplete system reset.

[0027] Preferably, in the above-mentioned control method for power-off and power-on of an automation equipment, in step S1, the PLC records the position information of the servo axis in each fixed scanning cycle, and the PLC assigns the unsigned 32-bit integer servo axis position information data in the pulse register to the power-off retention data register in each fixed scanning cycle.

[0028] The use of power-off retentive data registers can maintain the servo axis position information even in the event of a power outage, preventing data loss. By recording the servo axis position information in each scan cycle, data integrity and continuity are ensured.

[0029] Preferably, in the above-mentioned control method for power-off and voltage-continuation of automation equipment, in step S3, the PLC extracts the position information of the servo axis before power failure and assigns the position information data of the servo axis in the power-off retention data register to the pulse register.

[0030] After a power outage, the system can quickly retrieve the servo axis position information from the power-off retentive data register, enabling rapid recovery. When resuming production, the system can stably resume from the state before the power outage, enhancing system stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of the process of the present invention. DETAILED DESCRIPTION

[0032] The following is combined with Figure 1 The present invention is further described in detail with specific embodiments, but they are not intended to limit the present invention:

[0033] Example 1

[0034] A method for controlling power-off and voltage-continuation of automated equipment comprises the following steps:

[0035] S1: The device is powered on, the PLC keeps the state of the power-off hold relay unchanged, clears other relays, and then sets the value of the loop run switch to 1. The PLC records the position information of the servo axis in each fixed scan cycle. The PLC determines whether the device is shut down normally based on the state of the power-off hold relay. If so, it proceeds to step S2, otherwise it proceeds to step S3;

[0036] S2: Start the servo origin reset program. After the reset is completed, set the value of the servo reset completion flag to 1 and go to step S4;

[0037] S3: The PLC extracts the position information of the servo axis before power failure. The user chooses to continue press-fitting directly or continue press-fitting after resetting. After press-fitting is completed, the process goes to step S2.

[0038] S4: Check the automatic operation conditions. When the values ​​of the manual start switch, the cycle operation switch, and the servo reset completion switch are 1 and the value of the manual shutdown switch is 0, go to step S5. Otherwise, jump out of the automatic operation cycle and wait for the user to turn off the power.

[0039] S5: Start the press-fitting program, set the value of the cyclic operation switch to 0, use the power-off holding relay to start the servo press-fitting, and after the press-fitting is completed, clear the power-off holding relay, set the value of the cyclic operation switch to 1, and enter step S4.

[0040] Preferably, in step S5, a power-off holding type relay is used to start the servo press-fitting operation, and after each press-fitting operation, the value of the power-off holding type relay corresponding to the number of the press-fitting step is set to 1.

[0041] Preferably, in step S1, the PLC determines whether the equipment is shut down normally by the status of the power-off holding relay. When the value of each numbered power-off holding relay is 0, it is judged to be a normal shutdown. When the value of any numbered power-off holding relay is 1, it is judged to be a power-off shutdown.

[0042] Preferably, in step S3, continuing the press-fitting is continuing to run the press-fitting step before the power is turned off.

[0043] Preferably, in step S3, when the user chooses to continue press-fitting directly or to continue press-fitting after resetting, the value of the manual start switch is set to 1.

[0044] Preferably, in step S4, if the user chooses to turn on the manual shutdown and off-duty switch, the value of the manual shutdown and off-duty switch is set to 1.

[0045] Preferably, in step S4 , if the value of the servo reset completion flag is 1, the value of the servo reset completion switch is set to 1.

[0046] Preferably, in step S1, the PLC records the position information of the servo axis in each fixed scan cycle, and the PLC assigns the unsigned 32-bit integer servo axis position information data in the pulse register to the power-off retention data register in each fixed scan cycle.

[0047] Preferably, in step S3, the PLC extracts the position information of the servo axis before power failure, and the PLC assigns the position information data of the servo axis in the power-off retention data register to the pulse register.

[0048] like Figure 1 As shown, a Mitsubishi FX3U PLC can be used. Power on the device, initialize M8002, and reset the PLC's intermediate relays M0 to M499. M500 and above remain unchanged. Set the loop run switch M1 to 1. This allows the system to resume automatic operation after a power outage and restart, provided the reset conditions are met.

[0049] The M8000 operates in each scan cycle. The unsigned 32-bit integer data in the pulse register D8340 (for the Y0 axis example) is assigned to the power-off hold register D200. When pressure needs to be resumed after a power outage, the servo axis position information before the power outage is retrieved and assigned to D8340. Because the scan occurs once per cycle, position information may lag. The user can choose to reset and then resume pressure to eliminate position errors. Alternatively, if the user can accept errors only in the current step, they can select reset after resuming pressure. Both modes enable automatic pressure resumption after a power outage.

[0050] The PLC determines whether the device has shut down normally based on the status of the power-off latching relay M5. When the values ​​of M500-M599 are all 0, it is considered a normal shutdown. When the value of any of M500-M599 is 1, it is considered a power-off shutdown. If the power is off and the device is shut down, the user can choose to continue pressing directly or continue pressing after resetting. Continuing pressing after resetting is more optimal, as it avoids position errors caused by delayed recording. After the continued pressing is completed, the value of the servo reset completion flag M0 is 1, and the value of the servo reset completion switch M4 is 1. At this point, the status is consistent with that after a normal shutdown.

[0051] The user uses the manual switch to select to continue pressing directly or to continue pressing after resetting, so that the value of the manual start switch M2 is 1. In this way, after an abnormal power outage, the equipment can automatically run without anyone on duty. The manual shutdown switch M3 is not started at this time and the value is 0.

[0052] The PLC checks the automatic operation conditions. When the values ​​of the manual start switch M2, the cycle operation switch M1, and the servo reset completion switch M4 are 1 and the value of the manual shutdown switch M3 is 0, the press-fitting program is entered:

[0053] In the first step of press-fitting, use the power-off holding intermediate relay M500 to start the first step of servo press-fitting, and set the cyclic operation switch M1 to 0. The purpose of setting M1 to 0 is to prevent the program from being repeatedly executed and entering an infinite loop;

[0054] Press-fit step N, use the power-off hold-type intermediate relay M50N to start running the servo press-fit step N, where N is a single digit;

[0055] In the last step of press-fitting, step 100, the power-off holding intermediate relay M599 is used to start the servo press-fitting step 100, and the cyclic operation switch M1 is set to 1. Here, the last step is taken as step 100 as an example. In actual production, the required steps can be set as needed;

[0056] M500 to M599 correspond to steps 1 to 100 of the press-fitting process. During the first step of actual production, M1 is set to 0. At the last step of actual production, M5 is automatically cleared and M1 is set to 1. This allows for automatic looping. If more steps are required, M5000 to M5999 can be set to correspond to steps 1 to 6000 of the press-fitting process. This is just an example; set your settings accordingly.

[0057] The above pressing procedure should also be run when the power is cut off and the pressing can be continued from the steps before the power is cut off.

[0058] The user can flexibly select the downtime according to the production plan or other situations, and set the value of the manually selected shutdown switch M3 to 1. In this way, when the pressing program is completed, the PLC checks whether the automatic operation conditions are met, jumps out of the automatic cycle, and waits for the user to turn off the power.

[0059] When the user selects the "Continue Pressing After Reset" mode, the device will be initialized after an abnormal power outage. The servo origin reset procedure will be executed first. After the origin reset is completed, the press-fitting steps before the power outage will be continued. In this way, the origin reset can eliminate the hysteresis position recording error.

[0060] If the user selects the Direct Continue Pressing mode, the program will continue from the press-fitting step before the power outage to the last step. If there is only an error on one workpiece in the step before the power outage, it will not affect the unattended automatic operation.

[0061] In short, the above description is only a preferred embodiment of the present invention, and all equivalent changes and modifications made within the scope of the patent application of the present invention should fall within the scope of the present invention.

Claims

1. A method for controlling power outage and voltage continuation in automated equipment, characterized in that: The following steps are involved: S1: The device is powered on, the PLC keeps the state of the power-off latching relay unchanged, clears other relays, and then sets the value of the loop operation switch to 1. The PLC records the position information of the servo axis in each fixed scan cycle. The PLC determines whether the device is shut down normally based on the state of the power-off latching relay. When the value of each numbered power-off latching relay is 0, it is judged as a normal shutdown and the process goes to step S2. When the value of any numbered power-off latching relay is 1, it is judged as a power-off shutdown and the process goes to step S3. S2: Start the servo origin reset program. After the reset is completed, set the value of the servo reset completion flag to 1 and go to step S4; S3: The PLC extracts the position information of the servo axis before power failure. The user chooses to continue press-fitting directly or continue press-fitting after resetting. After press-fitting is completed, the process goes to step S2. S4: Check the automatic operation conditions. When the values ​​of the manual start switch, the cycle operation switch, and the servo reset completion switch are 1 and the value of the manual shutdown switch is 0, go to step S5. Otherwise, jump out of the automatic operation cycle and wait for the user to turn off the power. S5: Start the press-fitting program, set the value of the cyclic operation switch to 0, and use the power-off holding relay to start the servo press-fitting. In the press-fitting program, after each press-fitting, set the value of the power-off holding relay corresponding to the press-fitting number to 1. After the press-fitting program is completed, clear the power-off holding relay, set the value of the cyclic operation switch to 1, and enter step S4.

2. The method for controlling power outage and voltage continuation of automation equipment according to claim 1, characterized in that: In step S3, continuing the press-fitting is to continue running the press-fitting steps before the power is turned off.

3. The control method for power-off and voltage-continuation of automation equipment according to claim 1, characterized in that: In step S3, when the user chooses to continue press-fitting directly or to continue press-fitting after resetting, the value of the manual start switch is set to 1.

4. The method for controlling power outage and voltage continuation in automation equipment according to claim 1, characterized in that: In step S4, if the user chooses to turn on the manual shutdown and off-duty switch, the value of the manual shutdown and off-duty switch is set to 1.

5. The method for controlling power outage and voltage continuation of automation equipment according to claim 1, characterized in that: In step S4 , if the value of the servo reset completion flag is 1, the value of the servo reset completion switch is set to 1.

6. The method for controlling power outage and voltage continuation in automation equipment according to claim 1, characterized in that: In step S1, the PLC records the position information of the servo axis in each fixed scan cycle. The PLC assigns the unsigned 32-bit integer position information data of the servo axis in the pulse register to the power-off retention data register in each fixed scan cycle.

7. A control method for power-off and voltage-continuation of automation equipment according to claim 6, characterized in that: In step S3, the PLC extracts the position information of the servo axis before power failure, and the PLC assigns the position information data of the servo axis in the power-off retention data register to the pulse register.

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