Integrated controller and centralized control method

Abstract

The invention discloses an integrated controller and a centralized control method, and relates to the technical field of electrical equipment automatic control, and the integrated controller comprises a frequency determination module which determines the target frequency of a stretching motor according to the target frequency of a take-up motor and tension data; the sliding adjusting module is used for determining the frequency variable quantity of the take-up motor and the corresponding sliding frequency adjusting quantity, and adjusting the target frequency of the stretching motor according to the sliding frequency adjusting quantity; and the abrasion adjusting module is used for determining the current abrasion loss of the take-up wheel and the stretching device according to the abrasion model, determining the take-up abrasion frequency adjusting amount and the stretching abrasion frequency adjusting amount according to the current abrasion loss, and adjusting the target frequency of the take-up motor and the target frequency of the stretching motor according to the take-up abrasion frequency adjusting amount and the stretching abrasion frequency adjusting amount respectively. According to the characteristic data of the production equipment, the data used in the motor frequency calculation process are adjusted in advance, so that the calculation result is kept accurate all the time, and the product quality is improved.

Description

Technical Field

[0001] The present application relates to the technical field of automatic control of electrical equipment, and in particular to an integrated controller and a centralized control method. Background Art

[0002] Motors are widely used in automated production systems. Motors can not only provide rotational drive, but also linear drive. Through the rational use and combination of motors, various drive functions can be realized, providing unlimited possibilities for industrial production and control.

[0003] Most of the motors currently used are frequency-modulated motors, which control the working speed of the motors through frequency converters, thereby achieving control over the production process. Frequency converters are controllers, and each motor requires a controller. Therefore, when a large number of motors are used, multiple controllers need to be installed, resulting in high costs and complex installation. In order to reduce the use of controllers, the prior art proposes a technology for using one controller for multiple motors. For example, CN109240173A discloses an integrated control method and an integrated control device, which uses one controller to achieve the effect of controlling multiple motors in a scenario where multiple motors work together, such as a wire drawing machine, greatly saving the use of controllers.

[0004] However, the above patent relies on data determined by human experience when calculating the frequency of the motor, and this calculation process does not take into account the influencing factors of the actual production environment, such as wear, sliding friction, etc., resulting in a certain deviation between the calculated motor frequency and the actual required frequency, resulting in poor product quality. Summary of the invention

[0005] The embodiments of the present application provide an integrated controller and a centralized control method to solve the problem in the prior art that the influence factors of the actual production environment are not considered when calculating the motor frequency, resulting in poor applicability of the result.

[0006] On the one hand, an embodiment of the present application provides an integrated controller, including:

[0007] A data acquisition module is used to obtain the target frequency and tension data of the take-up motor;

[0008] A frequency determination module is used to determine the target frequency of the stretching motor according to the target frequency of the take-up motor and the tension data;

[0009] A motor driving module, used to drive the wire-receiving motor and the stretching motor to work according to the target frequency of the wire-receiving motor and the target frequency of the stretching motor respectively;

[0010] A sliding adjustment module is used to determine the frequency change of the take-up motor per unit time, and when the frequency change exceeds the sliding threshold, determine the sliding frequency adjustment amount corresponding to the frequency change amount, and adjust the target frequency of the stretching motor according to the sliding frequency adjustment amount;

[0011] The wear adjustment module is used to determine the current wear of the take-up wheel and the stretching device according to the wear model, determine the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount according to the current wear, and adjust the take-up motor target frequency and the stretching motor target frequency according to the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount.

[0012] On the other hand, the embodiment of the present application also provides a centralized control method, including:

[0013] Obtain the target frequency and tension data of the take-up motor;

[0014] Determine the target frequency of the stretching motor according to the target frequency of the take-up motor and the tension data;

[0015] According to the target frequency of the wire taking-up motor and the target frequency of the stretching motor, the wire taking-up motor and the stretching motor are driven to work respectively;

[0016] Determine the frequency change of the take-up motor per unit time, and when the frequency change exceeds the sliding threshold, determine the sliding frequency adjustment amount corresponding to the frequency change amount, and adjust the target frequency of the stretching motor according to the sliding frequency adjustment amount;

[0017] The current wear of the take-up wheel and the stretching device is determined according to the wear model, the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount are determined according to the current wear, and the take-up motor target frequency and the stretching motor target frequency are adjusted according to the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount.

[0018] An integrated controller and centralized control method in this application have the following advantages:

[0019] According to the characteristic data of the production equipment, the data used in the motor frequency calculation process is pre-adjusted to ensure that the calculation results are always accurate, thereby improving the quality of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0021] Figure 1A schematic diagram of the composition of a wire drawing machine using a centralized controller provided in an embodiment of the present application.

[0022] Figure 2 A flowchart of a centralized control method provided in an embodiment of the present application. DETAILED DESCRIPTION

[0023] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0024] Figure 1 A schematic diagram of the composition of a wire drawing machine using a centralized controller provided in an embodiment of the present application. The embodiment of the present application provides a centralized controller, including:

[0025] A data acquisition module is used to obtain the target frequency and tension data of the take-up motor;

[0026] A frequency determination module is used to determine the target frequency of the stretching motor according to the target frequency of the take-up motor and the tension data;

[0027] A motor driving module, used to drive the wire-receiving motor and the stretching motor to work according to the target frequency of the wire-receiving motor and the target frequency of the stretching motor respectively;

[0028] A sliding adjustment module is used to determine the frequency change of the take-up motor per unit time, and when the frequency change exceeds the sliding threshold, determine the sliding frequency adjustment amount corresponding to the frequency change amount, and adjust the target frequency of the stretching motor according to the sliding frequency adjustment amount;

[0029] The wear adjustment module is used to determine the current wear of the take-up wheel and the stretching device according to the wear model, determine the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount according to the current wear, and adjust the take-up motor target frequency and the stretching motor target frequency according to the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount.

[0030] Exemplarily, the wire drawing machine in the embodiment of the present application has two working states, one is switching from a stop state to a working state, and the other is always in a working state. In the first working state, the operator may stop the wire drawing machine for reasons such as maintenance or replacement of raw materials. At this time, the wire drawing machine will be in a stop state, and components such as the take-up motor, the take-up wheel, the stretching device and the stretching motor are all in a stationary state. The tension data at this time is pre-set by the operator. According to the pre-set tension data, the frequency determination module will first calculate the corresponding auxiliary frequency, and then use the take-up motor target frequency as the main frequency, and sum the main frequency and the auxiliary frequency to obtain the stretching motor target frequency.

[0031] In the second working state, the operator may change the target frequency of the take-up motor to increase or decrease the production speed of the drawn product. Once the target frequency of the take-up motor changes, the data acquisition module will be informed immediately and trigger the frequency determination module to recalculate the target frequency of the drawing motor. In this process, the tension data is measured by the tension meter on the drawn product.

[0032] exist Figure 1 In the drawing process, the tension meter includes a tension wheel, a tension rod and a potentiometer. The tension wheel is in direct contact with the drawn product and changes position as the tension of the drawn product changes. The position change is transmitted to the tension rod, which converts the position change into an angle change, and finally converted into a voltage change by the potentiometer. An increase or decrease in voltage represents a change in tension. After calibration, the specific correspondence between voltage change and tension change can be obtained. Therefore, the tension meter can measure the real-time tension data of the drawn product.

[0033] After measuring the tension data, the method for calculating the target frequency of the stretching motor is the same as that of the first working state, which will not be repeated here.

[0034] The sliding adjustment module monitors the frequency change during the process of the take-up motor switching from the stopped state to the working state. During the startup phase, the take-up motor will undergo a drastic speed change in a short period of time, and the wire drawing product will not undergo the same speed change as the take-up motor due to inertia. Therefore, there will be an instantaneous relative slip between the take-up wheel and the wire drawing product. The sliding adjustment module will monitor the slip of the take-up wheel relative to the wire drawing product at this time, and adjust the frequency of the stretching motor based on this slip situation to prevent the stretching motor from operating at the target frequency under normal working conditions, resulting in a reduction in the tension of the wire drawing product. After startup, the take-up wheel will move synchronously with the wire drawing product, so there is no need to monitor the slip situation.

[0035] The take-up wheel and the stretching device will wear out after long-term use, which is reflected in the data that the radius of the take-up wheel and the stretching device will decrease. At this time, if the motor frequency is still calculated according to the standard diameter, it will inevitably lead to a mismatch between the calculated motor frequency and the actual required motor frequency, which directly affects the quality of the wire drawing product. Therefore, the embodiment of the present application also calculates the wear amount of the take-up wheel and the stretching device based on the wear model, and then adjusts the motor frequency according to the wear amount, further improving the consistency between the calculated motor frequency and the actual demand.

[0036] In a possible embodiment, a storage module is further included, in which a sliding data table of each wire-drawn product is stored, and the sliding data table records the sliding amount under different frequency changes. After the sliding adjustment module determines the corresponding sliding amount according to the frequency change, it calculates the sliding frequency adjustment amount according to the parameters of the take-up wheel.

[0037] For example, due to the different properties of the wire drawing products, the amount of slip generated may be different under the same tension data and the same take-up wheel, so it is necessary to form a sliding data table according to the different wire drawing products. The sliding data table can be determined after a large number of experiments on the wire drawing products of each material. In the experiment, a variety of different tension data can be set in the wire drawing machine, and then multiple groups of experiments with different frequency changes are set under each tension data. Generally speaking, the greater the frequency change of the take-up motor, the more drastic the speed change of the take-up motor per unit time, and the correspondingly greater the slip. After collecting multiple groups of frequency change-slip data of the wire drawing products of each material, the least squares method can be used for function fitting, and the mapping function obtained by fitting is stored in the sliding data table. Before calculating the slip, the sliding adjustment module first obtains the name of the current wire drawing product, and then queries the storage module to obtain the sliding data table corresponding to the name, and uses the mapping function in the sliding data table to calculate the corresponding slip.

[0038] Furthermore, the sliding amount is expressed as a polynomial function established with the frequency change as the independent variable:

[0039] L=ax 2 +bx+c

[0040] Among them, L represents the sliding amount, x represents the frequency change, and a, b and c represent the coefficients of different terms.

[0041] The sliding adjustment module calculates the sliding frequency adjustment amount according to the following formula:

[0042]

[0043] Among them, Δf represents the sliding frequency adjustment amount, L represents the sliding amount, t represents the unit time, and r represents the radius of the take-up wheel.

[0044] After the sliding frequency adjustment amount is calculated, the difference between the stretching device target frequency and the sliding frequency adjustment amount can be calculated to obtain the adjusted stretching device target frequency.

[0045] In a possible embodiment, the wear model includes a take-up wheel wear model and a stretching device wear model, both of which are models established based on tension data and information about the wire-drawn product. After the take-up wheel and the stretching device are replaced, the wear adjustment module starts to count the working time and information about the wire-drawn product during each work, and determines the amount of take-up wheel wear generated in each work based on the take-up wheel wear model, working time, information about the wire-drawn product and tension data. The amount of stretching device wear generated in each work is determined based on the stretching device wear model, working time, information about the wire-drawn product and tension data. The take-up wheel wear is accumulated to obtain the current amount of take-up wheel wear, and the stretching device wear is accumulated to obtain the current amount of stretching device wear.

[0046] For example, since the functions of the take-up wheel and the stretching device are different, after working for the same time and with the same tension, the amount of wear on the two will also be different, so it is necessary to establish a take-up wheel wear model and a rope pulling device wear model respectively. Both wear models are obtained after long-term experiments. In the experiment, a variety of tension data can be set for each wire drawing product of different materials. Under each tension data, the wire drawing experiment is carried out for a sufficiently long time on the take-up wheel and the stretching device at the same time, and the wear of the take-up wheel and the stretching device is recorded. Based on these data, wear amount-time data of different tension data under various materials of wire drawing products can be formed. The corresponding mapping function can be obtained by fitting these data using the least squares method. Since the wear amount will only increase with the increase of time when the material and tension data of the wire drawing product are determined, the fitted mapping function is a linear function. After determining the mapping function, the wear amount under different usage time can be calculated.

[0047] Furthermore, the wear adjustment module determines the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount according to the following formula:

[0048]

[0049] Where Δf t Indicates the adjustment amount of the take-up wear frequency, f t Indicates the target frequency of the take-up motor, r t Indicates the radius of the take-up wheel before wear, Δr t Indicates the current wear of the take-up reel;

[0050]

[0051] Where Δf s Indicates the tensile wear frequency adjustment, f s represents the target frequency of the stretching motor, r s Indicates the radius of the stretching device before wear, Δr t Indicates the current amount of wear on the tensioner.

[0052] Since the radius of the take-up wheel and the stretching device will become smaller after wear, in order to maintain the same linear speed of the wire-drawn product before and after frequency adjustment, the take-up motor target frequency is adjusted to be the sum of the take-up motor target frequency and the take-up wear frequency adjustment amount, that is, a certain amount is increased on the basis of the original take-up motor target frequency, so that the take-up motor increases the rotation frequency when the radius is reduced, to ensure that the linear speed of the wire-drawn product remains unchanged. Correspondingly, the stretching motor target frequency is adjusted to be the sum of the stretching motor target frequency and the stretching wear frequency adjustment amount, that is, a certain amount is increased on the basis of the original stretching motor target frequency, so as to ensure that the linear speed of the wire-drawn product remains unchanged. When the linear speed of the wire-drawn product on the take-up wheel remains unchanged, and the linear speed of the wire-drawn product on the stretching device remains unchanged, not only the production speed of the wire-drawn product is guaranteed to remain unchanged, but also the tension data is guaranteed to remain unchanged, thereby improving the consistency of the quality of the wire-drawn product.

[0053] The present application also provides a centralized control method. Figure 2 As shown, the method comprises the following steps:

[0054] S200, obtaining target frequency and tension data of the take-up motor;

[0055] S210, determining a target frequency of the stretching motor according to the target frequency of the take-up motor and the tension data;

[0056] S220, driving the wire-receiving motor and the stretching motor to work respectively according to the target frequency of the wire-receiving motor and the target frequency of the stretching motor;

[0057] S230, determining a frequency change of the take-up motor per unit time, and when the frequency change exceeds a sliding threshold, determining a sliding frequency adjustment amount corresponding to the frequency change amount, and adjusting a target frequency of the stretching motor according to the sliding frequency adjustment amount;

[0058] S240, determine the current wear of the take-up wheel and the stretching device according to the wear model, determine the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount according to the current wear, and adjust the take-up motor target frequency and the stretching motor target frequency according to the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount.

[0059] Although the preferred embodiments of the present application have been described, those skilled in the art may make additional changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications falling within the scope of the present application.

[0060] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is also intended to include these modifications and variations.

Claims

1. An integrated controller, characterized in that: include: A data acquisition module is used to obtain the target frequency and tension data of the take-up motor; A frequency determination module, used to determine a target frequency of a stretching motor according to the target frequency of the take-up motor and the tension data; A motor driving module, used for driving the wire taking-up motor and the stretching motor to work respectively according to the target frequency of the wire taking-up motor and the target frequency of the stretching motor; A sliding adjustment module, used to determine the frequency change of the take-up motor per unit time, and when the frequency change exceeds a sliding threshold, determine a sliding frequency adjustment amount corresponding to the frequency change amount, and adjust the target frequency of the stretching motor according to the sliding frequency adjustment amount; The wear adjustment module is used to determine the current wear of the take-up wheel and the stretching device according to the wear model, determine the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount according to the current wear, and adjust the take-up motor target frequency and the stretching motor target frequency according to the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount.

2. An integrated controller according to claim 1, characterized in that: The sliding adjustment module monitors the frequency change in the process of the wire take-up motor switching from a stop state to a working state.

3. An integrated controller according to claim 1, characterized in that: It also includes a storage module, which stores a sliding data table for each wire-drawn product, and the sliding data table records the sliding amounts under different frequency changes. After the sliding adjustment module determines the corresponding sliding amount according to the frequency change, it calculates the sliding frequency adjustment amount according to the parameters of the take-up wheel.

4. An integrated controller according to claim 3, characterized in that: The sliding amount is expressed as a polynomial function established with the frequency change amount as the independent variable: L=ax 2 +bx+c Wherein, L represents the sliding amount, x represents the frequency change amount, and a, b and c represent coefficients of different items.

5. An integrated controller according to claim 3, characterized in that: The sliding adjustment module calculates the sliding frequency adjustment amount according to the following formula: Among them, Δf represents the sliding frequency adjustment amount, L represents the sliding amount, t represents the unit time, and r represents the radius of the take-up wheel.

6. An integrated controller according to claim 3, characterized in that: Before calculating the sliding amount, the sliding adjustment module first obtains the name of the product currently being drawn, and then searches the storage module to obtain the sliding data table corresponding to the name.

7. An integrated controller according to claim 1, characterized in that: The wear model includes a take-up wheel wear model and a stretching device wear model, both of which are models established based on the tension data and the information of the wire-drawn product. The wear adjustment module starts to count the working time and the information of the wire-drawn product during each work after the take-up wheel and the stretching device are replaced, and the amount of take-up wheel wear generated in each work is determined based on the take-up wheel wear model, the working time, the information of the wire-drawn product and the tension data. The amount of stretching device wear generated in each work is determined based on the stretching device wear model, the working time, the information of the wire-drawn product and the tension data. The take-up wheel wear is accumulated to obtain the current amount of take-up wheel wear, and the stretching device wear is accumulated to obtain the current amount of wear of the stretching device.

8. An integrated controller according to claim 7, characterized in that: The wear adjustment module determines the wire-receiving wear frequency adjustment amount and the stretching wear frequency adjustment amount according to the following formula: Where Δf t represents the adjustment amount of the take-up wear frequency, f t represents the target frequency of the take-up motor, r t Denotes the radius of the take-up wheel before wear, Δr t Indicates the current wear amount of the take-up wheel; Where Δf s represents the tensile wear frequency adjustment, f s represents the target frequency of the stretching motor, r s represents the radius of the stretching device before wear, Δr t Indicates the current wear amount of the stretching device.

9. An integrated controller according to claim 1, characterized in that: Before the wire-taking motor works, the tension data is preset by an operator, and during the working process of the wire-taking motor, the tension data is obtained by measuring the wire-drawn product with a tension meter.

10. A centralized control method applied to the integrated controller according to any one of claims 1 to 9, characterized in that: include: Obtain the target frequency and tension data of the take-up motor; Determine the target frequency of the stretching motor according to the target frequency of the take-up motor and the tension data; Driving the wire-receiving motor and the stretching motor to work respectively according to the wire-receiving motor target frequency and the stretching motor target frequency; Determine the frequency change of the take-up motor per unit time, and when the frequency change exceeds the sliding threshold, determine the sliding frequency adjustment amount corresponding to the frequency change amount, and adjust the target frequency of the stretching motor according to the sliding frequency adjustment amount; The current wear amounts of the take-up wheel and the stretching device are determined respectively according to the wear model, the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount are determined according to the current wear amounts, and the take-up motor target frequency and the stretching motor target frequency are adjusted respectively according to the take-up wear frequency adjustment amount and the stretching wear frequency adjustment amount.

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