Automatic roll changing system of lamination production line

Abstract

The invention provides an automatic roll changing system of a lamination production line, and belongs to the technical field of thin film processing and forming. A PLC (Programmable Logic Controller) control unit, a sensor signal acquisition unit, a position encoder, a reel motor encoder and an execution unit are arranged on the fixed frame; the PLC control unit is respectively in signal connection with the sensor signal acquisition unit, the position encoder and the execution unit and is used for realizing automatic roll changing; the sensor signal acquisition unit transmits data to the PLC control unit in real time, and the PLC control unit controls the execution unit to execute actions after receiving data signals. The position encoder collects position information in real time and feeds the position information back to the PLC control unit. The mode of introducing the PLC control unit, the sensor receiving unit and the execution units is adopted, continuous and stable automatic winding can be achieved, the automatic winding device is particularly suitable for thick paper base materials with the gram weight larger than 150 gsm, continuous production can be achieved without shutdown, the production cost is reduced, and the flexibility and adaptability of a production line are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of film processing and forming, and more specifically relates to an automatic roll changing system for a film laminating production line. Background Art

[0002] Thin film manufacturing technology occupies a core position in the field of materials science and engineering. The multi-link technology chain involved, from preparation to modification, coating, compounding and molding, is not only complex and sophisticated, but also has a profound impact on the development of multiple industries. With the advancement of science and technology, thin film manufacturing technology is undergoing unprecedented innovation. High-precision, nano-level and multifunctional technological breakthroughs have given thin film products higher performance and more diversified functions. At the same time, the global trend of environmental protection and sustainable development has also prompted the transformation of thin film manufacturing technology towards a greener and more energy-saving direction.

[0003] In the actual operation of film manufacturing, the production line is the key. Production lines such as biaxial stretching, cast film, extrusion lamination, blown film and coating transform raw materials into film products that meet various needs through precise mechanical devices and process flows. These production lines are not only widely used in packaging, construction, agriculture and other fields, but also promote technological innovation and industrial upgrading in related industries.

[0004] However, in the winding process of the extrusion composite production line, the existing winding technology faces many challenges. Especially for thick paper substrates, such as films with a grammage of more than 150gsm, tension control, surface flatness and winding stability during the winding process have become urgent problems to be solved. Although the traditional friction winding method can meet the winding needs to a certain extent, it often causes damage to the product surface and affects the quality of subsequent processing. More importantly, the existing production line needs to stop the machine when replacing the winding shaft, and then manually change the roll. This seriously restricts the continuity and efficiency of production. Especially in the extrusion composite production line, the high temperature working environment of the extruder and the need for continuous operation make stopping the machine to replace the winding shaft a problem that must be faced. This situation not only increases production costs, but also limits the flexibility and adaptability of the production line. Summary of the invention

[0005] The main purpose of the present application is to provide an automatic roll changing system for a laminating production line, which introduces a PLC control unit, a sensor receiving unit and various execution units to achieve continuous and stable automatic winding, especially suitable for thick paper substrates with a grammage greater than 150gsm. It can enable continuous production without stopping, thereby reducing production costs and improving the flexibility and adaptability of the production line.

[0006] In order to achieve the above-mentioned purpose, the present application proposes an automatic roll changing system for a laminating production line, wherein a PLC control unit, a sensor signal acquisition unit, a position encoder, a reel motor encoder, and an execution unit are installed on the fixed frame; The PLC control unit is respectively connected to the sensor signal acquisition unit, the position encoder, and the execution unit signal to realize automatic roll change; The sensor signal acquisition unit transmits data to the PLC control unit in real time, and the PLC controls the execution unit to execute the action after receiving the data signal; The position encoder collects position information in real time and feeds the position information back to the PLC control unit.

[0007] Furthermore, the execution unit includes: The flip frame is mounted on the fixed frame, and is flipped along the circumferential direction of the fixed frame by connecting a flip motor, the position encoder is connected to the flip motor electrical signal, and the flip motor is connected to the PLC control unit circuit; A knife holder assembly is hinged on the fixed frame and fixedly connected to a first power assembly, the knife holder assembly includes an upper knife holder and a lower knife holder, the first power assembly is connected to the PLC control unit circuit, and is used to drive the upper knife holder or the lower knife holder to move toward the film, and the upper knife holder and the lower knife holder are respectively equipped with a cutter; The push seat is mounted on the tool holder assembly and is connected to the PLC control unit by electrical signals. The end of the push seat facing the flip frame is the front limit point of the push seat, and the end away from the flip frame is the origin of the push seat. After the push seat reaches the origin, the flip frame flips. The position encoder feeds back the position of the flip frame in real time, and the new axis is automatically flipped to the position to be replaced. The unloading assembly is suspended on the fixed frame and arranged opposite to the knife holder assembly. The unloading assembly is provided with a second power assembly, which is connected to the PLC control unit circuit and is used to drive the unloading assembly to swing along the direction of film transfer.

[0008] Furthermore, the sensor signal acquisition unit includes: an origin detection sensor, an upper tool holder knife position sensor, a lower tool holder knife position sensor, a discharge arm position sensor, a discharge arm low position sensor, and a discharge arm lifting sensor, and the above sensors are respectively connected to the PLC control unit by electrical signals; The origin detection sensor is located on the horizontal push seat and is used to collect the origin position of the horizontal push seat; The upper tool holder knife position sensor and the lower tool holder knife position sensor are located on the tool holder assembly. When the PLC control unit receives the signal of the origin detection sensor, the tool holder automatically rises, that is, the upper tool holder descends to the roll changing position, waiting for roll changing; The unloading arm in-position sensor, the unloading arm low position sensor, and the unloading arm lifting sensor are respectively located on the unloading assembly and are used to collect position information of the unloading assembly.

[0009] Furthermore, when the PLC control unit collects signals from the upper tool holder tool position sensor and the lower tool holder tool position sensor, and the real-time production data meets the preset conditions of the new axis, the new axis is automatically pre-speeded to the synchronous speed consistent with the production line under the control of the PLC control unit.

[0010] Furthermore, the reel motor encoder is respectively connected to the PLC control unit and the reel motor electrical signal. When the speed of the reel motor encoder's real-time feedback is synchronized with the line speed, and when the real-time production data meets the preset reel changing conditions, the cutter executes the cutting action and performs the reel changing action. At the same time, the human-machine interface automatically records the production data of the finished reel and generates a production report.

[0011] Furthermore, after the automatic roll change, the unloading arm will automatically move up to the unloading position and automatically perform automatic unloading.

[0012] Furthermore, after the unloading arm reaches the unloading position, the unloading arm in-position sensor detects a signal, and the unloading fork automatically lifts up the shaft to complete the production; When the PLC control unit receives the signal from the unloading arm lifting sensor that the unloading fork is in place, it will lower the unloading arm and unload the finished product shaft.

[0013] Furthermore, the system also includes: a swing roller proportional valve and a swing roller sensor, which are respectively electrically connected to the PLC control unit and hung on the fixed frame for controlling the tension of the swing roller.

[0014] Furthermore, the swing roller sensor provides real-time feedback on the position of the swing roller, and controls the speed and torque of the shaft motor in real time through PID calculation. The swing roller proportional valve realizes multi-stage taper tension control, so that the finished product has a neat end surface with tight inside and loose outside.

[0015] The automatic roll changing system for a laminating production line proposed by the present invention has the following beneficial effects: The automatic roll changing system for the laminating production line proposed by the present invention is equipped with a PLC control unit, a sensor signal acquisition unit, a position encoder, a reel motor encoder and an execution unit on a fixed frame. The PLC control unit is respectively connected to the sensor signal acquisition unit, the position encoder and the execution unit signals to realize the automatic roll changing function. The sensor signal acquisition unit can collect data in real time and transmit it to the PLC control unit. After receiving the data signal, the PLC controls the execution unit to perform corresponding actions according to the preset logic. At the same time, the position encoder collects the position information of the reel and the motor in real time, and feeds back the precise position information to the PLC control unit to ensure the accuracy and stability of the roll changing process. The system is particularly suitable for thick paper substrates with a grammage greater than 150gsm, and can achieve continuous production without stopping the machine, which significantly reduces the production cost and improves the flexibility and adaptability of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the overall structure of the automatic roll changing system of the coating production line of the present invention.

[0017] In the figure, 1. fixed frame, 2. flip frame, 3. position encoder, 4. upper tool holder knife in place sensor, 5. lower tool holder knife in place sensor, 6. unloading arm in place sensor, 7. unloading arm low position sensor, 8. unloading arm lifting sensor, 9. swing roller proportional valve, 10. swing roller sensor, 11. alarm light, 12. push seat front limit, 13. push seat origin. DETAILED DESCRIPTION

[0018] The embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.

[0019] The following describes the embodiments of the present disclosure through specific examples, and those skilled in the art can easily understand other advantages and effects of the present disclosure from the contents disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, rather than all of the embodiments. The present disclosure can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present disclosure. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict. Based on the embodiments in the present disclosure, all other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of the present disclosure.

[0020] Example The existing production line needs to stop the machine to replace the reel, and then manually change the reel. This seriously restricts the continuity and efficiency of production. Especially in the extrusion composite production line, the high temperature working environment of the extruder and the need for continuous operation make stopping the machine to replace the reel a problem that cannot be faced. This situation not only increases production costs, but also limits the flexibility and adaptability of the production line.

[0021] Based on this, in order to solve the problem that continuous and stable automatic winding cannot be achieved when winding thick paper substrates (films greater than 150gsm), this embodiment provides an automatic roll changing system for a laminating production line, such as Figure 1 As shown, a PLC control unit, a sensor signal acquisition unit, a position encoder 3, a reel motor encoder and an execution unit are integrated on the fixed frame 1. The PLC control unit is connected to the sensor signal acquisition unit, the position encoder 3 and the execution unit through signal connection, and is responsible for realizing the control of the entire automatic roll changing process. The sensor signal acquisition unit is responsible for real-time data collection and transmission of these data to the PLC control unit; after receiving these data signals, the PLC control unit will control the execution unit to perform corresponding actions accordingly. At the same time, the position encoder 3 also collects position information in real time, and feeds this position information back to the PLC control unit in real time to ensure the accuracy of the roll changing process.

[0022] It should be noted that the model of the PLC control unit used in this system is the Siemens 1500 series. The Siemens 1500 series PLC is famous for its high performance, high reliability and scalability, and can perfectly match the requirements of the automatic roll changing system of the laminating production line for precise control, rapid response and complex logic processing. Its powerful processing capability ensures the rapid analysis and decision-making of the real-time data of the sensor signal acquisition unit, thereby realizing the precise control of the execution units such as the flip frame, the tool holder assembly, the push seat and the unloading assembly. In addition, the Siemens 1500 series PLC provides a wealth of communication interfaces and programming environments, which facilitates system integration and subsequent maintenance and upgrades, and enhances the flexibility and scalability of the system. More importantly, this series of PLCs has a wide range of applications and mature solutions in the field of industrial automation, which helps to reduce the system failure rate, improve overall production efficiency and product quality, and bring long-term economic benefits to the enterprise.

[0023] In order to further illustrate the execution process of the execution unit, the execution unit of the present invention is constructed as follows: it includes a flip frame 2 mounted on the fixed frame 1, and the flip frame 2 is flipped along the circumferential direction of the fixed frame 1 by a flip motor, wherein the position encoder 3 is connected to the flip motor electrical signal, and the flip motor is connected to the PLC control unit circuit. In addition, the execution unit also includes a tool holder assembly hinged on the fixed frame 1, which is composed of an upper tool holder and a lower tool holder, and is fixedly connected to a first power assembly, which is connected to the PLC control unit circuit and is used to drive the upper tool holder or the lower tool holder to move toward the film, and the upper tool holder and the lower tool holder are respectively equipped with a cutter. At the same time, the execution unit is also provided with a flat push seat mounted on the tool holder assembly, which is connected to the PLC control unit electrical signal, one end of the flat push seat is facing the front limit point of the flip frame 2, and the other end is away from the origin of the flip seat, when the flat push reaches the origin position, the flip frame 2 will flip, and the position encoder 3 will feedback the position information of the flip frame 2 in real time to ensure that the new axis can be automatically flipped to the position to be replaced. Finally, the execution unit also includes a discharge assembly suspended on the fixed frame 1 and arranged opposite to the knife holder assembly. The assembly is provided with a second power assembly, which is connected to the PLC control unit circuit and is used to drive the discharge assembly to swing along the film transfer direction. This system realizes the high automation and intelligence of the automatic roll changing process on the laminating production line by integrating the execution units such as the flip frame 2, the knife holder assembly, the push seat and the discharge assembly. The flip frame 2 ensures the smooth switching of the new and old winding shafts through the precise control of the flip motor and the real-time feedback of the position encoder 3, thereby improving the efficiency and accuracy of the roll changing. The upper and lower knife holders in the knife holder assembly are driven by the first power assembly, which can quickly and accurately complete the film cutting operation, effectively avoiding the production interruption caused by stopping for roll changing, while maintaining the integrity of the product surface and improving the product quality. The design of the push seat makes the switching of the new and old shafts smoother during the roll changing process. Through the precise monitoring of the position encoder 3, the real-time confirmation of the new shaft in place is realized, further enhancing the continuous operation capability of the system. The unloading component uses the drive of the second power component to realize the automatic unloading of the old roll, which not only reduces the labor intensity of manual labor, but also significantly improves the overall operation efficiency of the production line. In summary, the automatic roll changing system of the laminating production line significantly improves the automation level of the production line, enhances production flexibility, reduces downtime, effectively controls production costs, and ensures product quality, meeting the urgent needs of modern industry for efficient, continuous and intelligent production lines.

[0024] It should be noted that the first power assembly and the second power assembly may be composed of a hydraulic system, such as a hydraulic cylinder, a hydraulic motor, a pipeline, etc.; or may be composed of an electric drive system such as a telescopic motor.

[0025] At the same time, in order to further illustrate the process of sensor signal transmission, the sensor signal acquisition unit includes the origin detection sensor, the upper tool holder knife position sensor 4, the lower tool holder knife position sensor 5, the unloading arm position sensor 6, the unloading arm low position sensor 7 and the unloading arm lifting sensor 8, all of which are connected to the PLC control unit through electrical signals. The origin detection sensor is set on the horizontal push seat, and its function is to collect the origin position information of the horizontal push seat. The upper tool holder knife position sensor 4 and the lower tool holder knife position sensor 5 are placed on the tool holder assembly. When the PLC control unit receives the signal from the origin detection sensor, it will trigger the automatic rise of the tool holder, which is specifically manifested as the upper tool holder descending to the roll changing position to prepare for the roll changing operation. The unloading arm position sensor 6, the unloading arm low position sensor 7 and the unloading arm lifting sensor 8 are respectively deployed on the unloading assembly, and their task is to collect the real-time position information of the unloading assembly. This system realizes accurate monitoring and feedback of each key link in the automatic roll changing process of the laminating production line by introducing comprehensive sensor signal acquisition units such as origin detection sensor, upper knife holder knife position sensor 4, lower knife holder knife position sensor 5, unloading arm position sensor 6, unloading arm low position sensor 7 and unloading arm lifting sensor 8. The origin detection sensor ensures that the starting position of the push seat action is accurate, laying a solid foundation for the entire roll changing process. The setting of the upper knife holder knife position sensor 4 and the lower knife holder knife position sensor 5 makes the action of the knife holder assembly more reliable, and can quickly and accurately reach the predetermined position after receiving the command of the PLC control unit, effectively improving the cutting efficiency and safety. The unloading arm position sensor 6, the unloading arm low position sensor 7 and the unloading arm lifting sensor 8 on the unloading assembly together constitute a full-scale monitoring of the unloading process, ensuring the smooth unloading of the old roll, while avoiding production accidents caused by misoperation or sensor failure. The integrated application of these sensors not only significantly improves the system's degree of automation and intelligence, but also enhances the system's stability and reliability, further improving the continuous production capacity of the laminating production line and providing a strong guarantee for achieving efficient and high-quality production goals.

[0026] In some embodiments, when the PLC control unit collects the signals of the upper tool holder knife position sensor 4 and the lower tool holder knife position sensor 5, and the real-time production data meets the preset conditions of the new axis, the new axis automatically pre-speeds to the synchronous speed consistent with the production line under the control of the PLC control unit. This design enables the automatic roll changing system of the laminating production line to realize the automation and intelligence of the new axis pre-speed under the precise management of the PLC control unit. When the PLC control unit accurately receives the signals of the upper tool holder knife position sensor 4 and the lower tool holder knife position sensor 5, and confirms that the real-time production data meets the preset conditions of the new axis, it can quickly start the preset program to control the new axis to automatically pre-speed to the synchronous speed that is completely consistent with the production line. This function not only greatly shortens the speed matching time during the roll changing process, reduces the speed fluctuation of the production line, thereby ensuring the stability of product quality, but also further improves the continuous operation capacity and overall production efficiency of the production line. In addition, the design also reflects the high flexibility and adaptability of the system, which can automatically adjust the roll changing process according to different production needs and conditions to ensure the smooth progress of the production process, creating greater economic benefits for the enterprise.

[0027] In some embodiments, the reel motor encoder is connected to the PLC control unit and the reel motor electrical signal respectively. When the speed of the reel motor encoder real-time feedback is synchronized with the line speed, and when the real-time production data meets the preset roll-changing conditions, the cutter performs the cutting action and performs the roll-changing action. At the same time, the human-machine interface automatically records the production data of the finished roll and generates a production report. Through the close linkage of the reel motor encoder, the PLC control unit and the reel motor, the automatic roll-changing system of the laminating production line realizes the precise monitoring and adjustment of the real-time speed of the reel motor. When the speed of the reel motor encoder feedback is perfectly synchronized with the line speed of the production line, and the real-time production data meets the preset roll-changing conditions, the system can automatically trigger the cutter to perform the cutting action to ensure the accuracy of the roll-changing process. This design not only further improves the roll-changing efficiency, but also ensures the flatness and accuracy of the product cutting, meeting the stringent requirements of high-quality production. At the same time, the function of the human-machine interface to automatically record the production data of the finished roll and generate a production report provides production managers with detailed and accurate production information, which is convenient for production analysis, cost control and quality traceability, and greatly improves the scientificity and efficiency of production management.

[0028] After the system changes the roll automatically, the unloading arm will automatically move up to the unloading position and automatically perform automatic unloading. That is, after the unloading arm reaches the unloading position, the unloading arm in-place sensor 6 detects the signal, and the unloading fork automatically lifts the finished shaft; when the PLC control unit receives the unloading fork in-place signal from the unloading arm lifting sensor 8, it will lower the unloading arm and unload the finished shaft. This solution enables the unloading process of the automatic roll changing system of the laminating production line to achieve a high degree of automation and precise control. After the unloading arm reaches the preset unloading position, the unloading arm in-place sensor 6 can quickly detect the signal and trigger the unloading fork to automatically lift up, accurately completing the unloading preparation of the production shaft. When the PLC control unit receives the unloading fork in-place signal fed back by the unloading arm lifting sensor 8, the system will immediately execute the unloading arm lowering action to smoothly unload the finished shaft. This coherent automated process not only significantly improves the unloading efficiency, reduces the complexity and time cost of manual operation, but also ensures the stability and safety of the unloading process, avoiding production accidents caused by misoperation or human factors. In addition, the design also enhances the reliability and durability of the system, enabling the laminating production line to maintain efficient and stable operation in a high-intensity, continuous production environment, creating greater economic benefits and competitive advantages for the company.

[0029] In some embodiments, the system further includes: a swing roller proportional valve 9 and a swing roller sensor 10, which are electrically connected to the PLC control unit and are mounted on the fixed frame 1 to control the tension of the swing roller. By introducing the swing roller proportional valve 9 and the swing roller sensor 10, the system realizes the precise control of the tension of the swing roller, and further improves the performance and stability of the automatic roll changing system of the laminating production line. The swing roller proportional valve 9 can accurately adjust the tension of the swing roller according to the instructions of the PLC control unit, ensure the smooth transition of the film during the roll changing process, and avoid problems such as film breakage or poor winding caused by tension fluctuations. At the same time, the swing roller sensor 10 monitors the state of the swing roller in real time, transmits the data to the PLC control unit, and provides key feedback information for the system, so that the system can be dynamically adjusted according to the actual production situation to ensure that the swing roller is always in the best working state. This design not only improves the winding quality and production efficiency of the film, but also enhances the adaptive ability and intelligence level of the system, so that the laminating production line can show more outstanding performance and stability when dealing with the production of films of different materials and specifications, creating greater production value and market competitiveness for the enterprise.

[0030] More specifically, the swing roller sensor 10 feeds back the position of the swing roller in real time, controls the speed and torque of the shaft motor in real time through PID calculation, and realizes multi-stage taper tension control through the swing roller proportional valve 9, so that the end surface of the finished product is tight inside and loose outside and neat. This system uses the swing roller sensor 10 to feed back the swing roller position information in real time, combines PID calculation to accurately control the speed and torque of the shaft motor, and realizes multi-stage taper control of film tension. This innovative design not only ensures the ideal state of the finished film being tight inside and loose outside, effectively avoids the problem of film deformation or relaxation caused by uneven tension, but also makes the end surface of the finished product more neat, meeting the stringent requirements of high-quality production. At the same time, the realization of multi-stage taper tension control also enhances the system's adaptability to films of different materials and thicknesses, allowing the laminating production line to maintain excellent performance and stability in a wider range of production scenarios. In addition, the design also improves production efficiency, reduces scrap rate, and creates greater economic benefits for the company.

[0031] In the above process, the swing roller sensor feeds back the position of the swing roller in real time as the process value, and the middle value of the swing roller is calibrated as the target value. The speed of the shaft motor is adjusted in real time through PID (proportional-integral-differential control) to maintain the stability of the tension. Among them, the taper tension formula is: In this system, the tension control of multi-stage taper is the setting value of multi-stage taper with multiple roll diameters on the human-machine interface. The current real-time Taper setting value is calculated according to the real-time roll diameter; and the real-time production tension is calculated through the diameter-taper tension formula. The tension setting is set by the given air pressure of the electronically controlled proportional valve, so that the tension control of multi-stage taper is realized through the swing roller proportional valve.

[0032] In the actual production process, the automatic roll changing steps of this system are as follows: Step 1. There are three automatic roll changing modes for winding: a. length roll changing mode, b. diameter roll changing mode, and c. roll-to-roll roll changing mode. During the continuous production process, the PLC program calculates the length and diameter of the current roll in real time. When the real-time data meets the roll changing preparation conditions of the current winding and roll changing mode, the winding alarm light will continuously alarm for 6 seconds, alerting the surrounding operators to safety in advance.

[0033] Step 2: After the alarm light comes on, the push seat automatically retreats to the origin position and the origin detection sensor feeds back to the PLC Step 3: After the horizontal push reaches the horizontal push seat origin 13, the turning frame 2 automatically turns over, and the position encoder 3 feeds back the position of the turning frame 2 in real time, and the new axis automatically turns over to the position to be replaced.

[0034] Step 4: After the turning frame 2 turns the new shaft into place, the push seat will automatically move forward to the front limit position 12 of the push seat, that is, the new shaft roll changing position.

[0035] Step 5: PLC receives the signal from the roll pusher in place sensor, and the knife holder automatically rises (upper knife descends) to the roll changing position, waiting for roll changing.

[0036] Step 6: After the PLC receives the signal from the tool holder in-position sensor and the real-time production data meets the new axis pre-speed conditions, the new axis will automatically pre-speed to the synchronous speed consistent with the production line.

[0037] Step 7. When the speed of the reel motor encoder real-time feedback is synchronized with the line speed, and when the real-time production data meets the preset roll-changing conditions, the cutter performs the cutting action and the roll-changing action is performed. At the same time, the human-machine interface automatically records the production data of the finished roll and generates a production report.

[0038] Step 8: The new shaft will be automatically wound according to the preset production parameters. The production parameter operator can set or call the formula parameters on the human-machine interface according to the products produced. The stability of the automatic winding tension is achieved by using the swing roller sensor 10 to feedback the position of the swing roller in real time, and the speed and torque of the shaft motor are controlled in real time through PID calculation, and the swing roller proportional valve 9 is used to realize multi-stage taper tension control, so that the finished product is tight inside and loose outside, and the end surface is neat, so as to achieve a tight and neat winding effect for the whole roll.

[0039] Step 9: After the roll is automatically changed, the unloading arm will automatically move to the unloading position and automatically unload the rolls.

[0040] Step 10: After the unloading arm reaches the unloading position and the in-position sensor detects a signal, the unloading fork automatically lifts up the shaft to complete the production.

[0041] Step 11: After the PLC receives the signal that the unloading fork is in place, it will lower the unloading arm and unload the finished shaft.

[0042] Step 12: The operator cooperates with the core puller to pull out the air shaft, install a new paper tube, and stick the tape on it. Then, put the air shaft back on the unloading fork and press the shaft installation button.

[0043] Step 13. After the PLC receives the rear shaft installation instruction, the unloading arm will automatically install the air-expanding shaft back into the reel, and the pneumatic clamping device of the reel automatically clamps the air-expanding shaft. At the same time, the unloading arm automatically moves to the lowest position and waits for the next instruction.

[0044] After step 13 is completed, the entire automatic winding production process is completed. During this process, the alarm light will sound for 1 second and stop for 1 second. In the normal production process, the winding will automatically execute steps 1-13 to achieve continuous production without stopping.

[0045] In the above steps, the human-machine interface has three automatic roll changing modes: length roll changing, diameter roll changing, and roll-to-roll. For example, when length roll changing is selected, the production length is set to 5000M, the production line speed is 300M / min, the roll changing preparation time is 2min decimeter, and the pre-speed time is 0.3min. Then, when the production reaches 4310M, the reel will automatically prepare for roll changing, and when the production reaches 4910M, it will automatically pre-speed, and the roll will be changed when the production reaches 5000M.

[0046] In the present invention, the parameters are as follows: 1. Roll diameter range: minimum diameter: 100mm; maximum diameter: 1800mm.

[0047] 2. Start-up tension range: 50-550N.

[0048] 3. Speed ​​range: Maximum line speed: 180m / min; Minimum production speed 50m / min.

[0049] 4. Motor parameters: Motor rated speed: 1500r / min; theoretical maximum operating frequency: 130Hz.

[0050] 5. Maximum roll weight: 1800kg.

[0051] Among them, according to the power system calculation: 1. Speed: Speed ​​range of air shaft: 1), 180 / (3.14*0.1)=573.2r / min; 2), 50 / (3.14*1.8)=8.85r / min.

[0052] 2. Motor speed range (under the premise of controlled output torque): 58r / min (2Hz*29)-3480r / min (120Hz*29), the total reduction ratio is: 58 / 8.85=6.55; 3480 / 573.2=6.07; the final decision is to take the total speed ratio as 6.3; this ensures stable torque output when the roll is large, and when the roll is small, the torque required is less, so it can be overclocked appropriately.

[0053] 3. Calculate the maximum torque: 550N*0.9m=495Nm. Reversely calculate the maximum torque that the motor needs to provide: 495 / 6.3=78.5Nm, which corresponds to a 15KW four-pole variable frequency motor.

[0054] In order to consider the moment of inertia at the maximum roll and ensure the response stiffness of the instantaneous output, the calculation safety factor of the torque needs to be set to 2, and the motor power is selected as a 30-kilowatt four-level variable frequency motor, which is equipped with a heavy-duty inverter drive. It can be seen that the present invention can meet the continuous torque stability of high-weight paper winding, and can cope with the response stiffness of high torque and large roll weight, so that the equipment can meet the response requirements of high and low speeds, large and small roll diameters, and different roll weights, so that when winding a large-weight product, a moderately tight roll can be wound, so that the entire winding process is smooth and stable.

[0055] Therefore, the automatic roll changing system of the laminating production line proposed by the present invention is equipped with a PLC control unit, a sensor signal acquisition unit, a position encoder, a reel motor encoder and an execution unit on a fixed frame. The PLC control unit is respectively connected to the sensor signal acquisition unit, the position encoder and the execution unit signal to realize the automatic roll changing function. The sensor signal acquisition unit can collect data in real time and transmit it to the PLC control unit. After receiving the data signal, the PLC controls the execution unit to perform corresponding actions according to the preset logic. At the same time, the position encoder collects the position information of the reel and the motor in real time, and feeds back the precise position information to the PLC control unit to ensure the accuracy and stability of the roll changing process. The system is particularly suitable for thick paper substrates with a grammage greater than 150gsm, and can achieve continuous production without stopping, which significantly reduces production costs and improves the flexibility and adaptability of the production line.

[0056] In the description of the present invention, it is necessary to understand that the terms "middle", "length", "up", "down", "front", "back", "vertical", "horizontal", "inside", "outside", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0057] In the present invention, unless otherwise clearly specified and limited, the first feature "on" the second feature may be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. "Multiple" means at least two, such as two, three, etc., unless otherwise clearly and specifically limited.

[0058] In the present invention, unless otherwise clearly defined and specified, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0059] The above is only for explaining the implementation mode of the present invention and is not intended to limit the present invention. For those skilled in the art, any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention without creative work should be included in the protection scope of the present invention.

Claims

1. The automatic roll changing system of the laminating production line includes a fixed frame, characterized in that: A PLC control unit, a sensor signal acquisition unit, a position encoder, a reel motor encoder, and an execution unit are installed on the fixed frame; The PLC control unit is respectively connected to the sensor signal acquisition unit, the position encoder, and the execution unit signal to realize automatic roll change; The sensor signal acquisition unit transmits data to the PLC control unit in real time, and the PLC controls the execution unit to execute the action after receiving the data signal; The position encoder collects position information in real time and feeds the position information back to the PLC control unit.

2. The automatic roll changing system for laminating production line according to claim 1 is characterized in that: The execution unit comprises: The flip frame is mounted on the fixed frame, and is flipped along the circumferential direction of the fixed frame by connecting a flip motor, the position encoder is connected to the flip motor electrical signal, and the flip motor is connected to the PLC control unit circuit; A knife holder assembly is hinged on the fixed frame and fixedly connected to a first power assembly, the knife holder assembly includes an upper knife holder and a lower knife holder, the first power assembly is connected to the PLC control unit circuit, and is used to drive the upper knife holder or the lower knife holder to move toward the film, and the upper knife holder and the lower knife holder are respectively equipped with a cutter; The push seat is mounted on the tool holder assembly and is connected to the PLC control unit by electrical signals. The end of the push seat facing the flip frame is the front limit point of the push seat, and the end away from the flip frame is the origin of the push seat. After the push seat reaches the origin, the flip frame flips. The position encoder feeds back the position of the flip frame in real time, and the new axis is automatically flipped to the position to be replaced. The unloading assembly is suspended on the fixed frame and arranged opposite to the knife holder assembly. The unloading assembly is provided with a second power assembly, which is connected to the PLC control unit circuit and is used to drive the unloading assembly to swing along the direction of film transfer.

3. The automatic roll changing system for the laminating production line according to claim 2 is characterized in that: The sensor signal acquisition unit includes: an origin detection sensor, an upper tool holder knife position sensor, a lower tool holder knife position sensor, a discharge arm position sensor, a discharge arm low position sensor, and a discharge arm lifting sensor, and the above sensors are respectively connected to the PLC control unit by electrical signals; The origin detection sensor is located on the horizontal push seat and is used to collect the origin position of the horizontal push seat; The upper tool holder knife position sensor and the lower tool holder knife position sensor are located on the tool holder assembly. When the PLC control unit receives the signal of the origin detection sensor, the tool holder automatically rises, that is, the upper tool holder descends to the roll changing position, waiting for roll changing; The unloading arm in-position sensor, the unloading arm low position sensor, and the unloading arm lifting sensor are respectively located on the unloading assembly and are used to collect position information of the unloading assembly.

4. The automatic roll changing system for the laminating production line according to claim 3 is characterized in that: When the PLC control unit collects signals from the upper tool holder tool position sensor and the lower tool holder tool position sensor, and the real-time production data meets the preset conditions of the new axis, the new axis is automatically pre-speeded to the synchronous speed consistent with the production line under the control of the PLC control unit.

5. The automatic roll changing system for laminating production line according to claim 3 is characterized in that: The reel motor encoder is respectively connected to the PLC control unit and the reel motor electrical signal. When the speed of the reel motor encoder's real-time feedback is synchronized with the line speed, and when the real-time production data meets the preset reel changing conditions, the cutter performs the cutting action and performs the reel changing action. At the same time, the human-machine interface automatically records the production data of the finished reel and generates a production report.

6. The automatic roll changing system for laminating production line according to claim 3 is characterized in that: After the roll is automatically changed, the unloading arm will automatically move to the unloading position and automatically unload the rolls.

7. The automatic roll changing system for laminating production line according to claim 6 is characterized in that: After the unloading arm reaches the unloading position, the unloading arm in-place sensor detects a signal, and the unloading fork automatically lifts up the shaft to complete the production; When the PLC control unit receives the signal from the unloading arm lifting sensor that the unloading fork is in place, it will lower the unloading arm and unload the finished product shaft.

8. The automatic roll changing system for laminating production line according to claim 1 is characterized in that: Also includes: The swing roller proportional valve and the swing roller sensor are respectively electrically connected to the PLC control unit and hung on the fixed frame to control the tension of the swing roller.

9. The automatic roll changing system for laminating production line according to claim 8, characterized in that: The swing roller sensor provides real-time feedback on the position of the swing roller, and the speed of the shaft motor is adjusted in real time through PID calculation. The swing roller proportional valve is used to achieve multi-stage taper tension control, making the finished product tight inside and loose outside with neat end surfaces.

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