Automatic horizontal loading control system and control method based on embedded system

Abstract

The invention provides an automatic horizontal loading control system and method based on an embedded system. The system comprises a handheld box, an upper computer, an embedded loading control unit, an execution mechanism driven by a servo motor, a proximity switch and a pressure sensor, wherein the handheld box and the upper computer are used for issuing instructions; the handheld box is connected to the loading control unit and issues an instruction to the loading control unit. Compared with traditional manual loading, a scheme based on an embedded real-time system is adopted, the loading precision can be improved, and abnormal conditions can be responded more quickly; and a partially automatic control flow is adopted, so that the labor intensity of workers can be reduced, and the loading time is shortened.

Description

Technical Field

[0001] The invention belongs to the technical field of equipment horizontal loading, and in particular relates to an automatic horizontal loading control system and a control method based on an embedded system. Background Art

[0002] At present, the loading of large cylindrical equipment in China is still mainly done by manual lifting, which has many problems. For example, the equipment is heavy and large in size, and there are safety issues during the lifting and transportation process; the lifting and loading process relies on experienced operators, and improper operation will cause excessive local pressure on the equipment, resulting in equipment damage; the manual loading process is labor-intensive and inefficient. Therefore, there is an urgent need for an efficient, safe, reliable, and automated loading control system and loading method. Summary of the invention

[0003] In view of the problems existing in the current horizontal loading process, the purpose of the present invention is to propose an automatic horizontal loading control system and control method based on an embedded system, which is used for horizontal loading of large cylindrical equipment into a cylindrical barrel channel, which can improve the accuracy and reliability of horizontal loading and realize intelligent and digital production; it can improve the level of automation in the horizontal loading process, thereby reducing the workload of workers and shortening the loading cycle; and improve the safety of the loading process.

[0004] The technical solution to achieve the purpose of the present invention is:

[0005] An automatic horizontal loading control system based on an embedded system, comprising a handheld box and a host computer for issuing instructions, an embedded loading control unit, an actuator driven by a servo motor, a proximity switch and a pressure sensor; wherein:

[0006] The handheld box is connected to the loading control unit and sends instructions to the loading control unit;

[0007] The host computer communicates with the loading control unit, and the host computer sends control instructions to the loading control unit;

[0008] The actuator is connected to the loading control unit and receives instructions from the loading control unit;

[0009] Proximity switches are installed at the front and end of the actuator, respectively, and are connected to the loading control unit to feed back the current equipment in-place status to the loading control unit;

[0010] The pressure sensor is installed on the top of the actuator and connected to the loading control unit, so that the loading control unit can obtain the pressure;

[0011] The loading control unit receives instructions from the handheld box and the host computer at the same time, determines the current instruction according to the priority, receives feedback from the proximity switch and pressure sensor, and realizes the motion protection of the actuator and automatic stop in place.

[0012] Furthermore, the instructions include enable, load, stop and speed.

[0013] Furthermore, a servo motor is provided inside the actuator, and the forward and reverse rotation of the servo motor drives the actuator forward and backward; a brake is provided on the motor, and the current position is locked by the brake when the actuator stops.

[0014] Furthermore, the handheld box is connected to the loading control unit via an IO interface.

[0015] Furthermore, the host computer communicates with the loading control unit via RS485.

[0016] Furthermore, the actuator is connected to the loading control unit via a CAN bus.

[0017] Furthermore, a proximity switch installed at the end of the actuator is 20 mm away from the end edge and is connected to the loading control unit via IO.

[0018] Furthermore, the pressure sensors include two and are connected to the AD interface of the loading control unit.

[0019] Furthermore, the loading control unit adopts inner and outer two-layer state machines to decouple the emergency matters and routine matters. The outer state machine is responsible for handling emergency matters, including not enabled, handheld box enabled state, industrial computer enabled, industrial computer enabled switching to handheld box enabled, stopped, faulty shutdown, emergency shutdown and emergency stop state. Based on the priority of the matters, these 9 states are used to handle the conflict between the handheld box and the host computer commands, fault conditions and emergency shutdown matters; the inner state machine is responsible for handling routine matters, including 2 states: idle and loading.

[0020] An automatic horizontal loading control method based on an embedded system, comprising:

[0021] Step 1: Use the host computer or handheld box to issue an enable command;

[0022] Step 2: After the loading control unit receives the enable, the outer state machine jumps into the enable state, enables the servo motor, and opens the brake;

[0023] Step 3: After enabling, use the handheld box or host computer to issue the loading command;

[0024] Step 4: The loading control unit receives the loading instruction and starts to execute the loading process. The inner state machine jumps into the loading state and sends a forward instruction to the actuator, and the actuator starts to move forward.

[0025] Step 5: During the loading process, the rising edge of the proximity switch at the front end of the actuator is triggered, the inner state machine jumps into the idle state, and the actuator stops;

[0026] Step 6: When the top of the equipment correctly enters the barrel channel and there is no interference, use the host computer or handheld box to issue the loading instruction again, execute the loading process, and the actuator continues to move forward;

[0027] Step 7: Trigger the rising edge of the proximity switch 2 at the end of the actuator, and the forward speed of the actuator is decelerated to the set first-level deceleration speed;

[0028] Step 8: After continuing to move forward 10 mm, the forward running speed of the actuator is automatically decelerated to the set secondary deceleration speed, and the sum F of the pressure values ​​of the two pressure sensors at this time is obtained;

[0029] Step nine, the actuator continues to move forward at the secondary deceleration speed, and stops automatically when the sum of the monitored pressure values ​​rises from F to F+Δ, and the loading operation is completed; wherein Δ is the set pressure rise threshold.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] (1) The present invention uses a variety of sensors including proximity switches and pressure sensors, which can monitor the stress conditions during loading in real time and immediately shut down the machine when a fault occurs to avoid damage to the equipment;

[0032] (2) Compared with manual lifting and loading throughout the entire process, the loading time can be shortened from 30 minutes or even longer to 5 minutes, effectively reducing labor intensity and improving loading efficiency;

[0033] (3) A two-layer state machine is used to decouple emergency matters and routine operations, which improves the real-time processing of abnormal situations and improves the safety of loading;

[0034] (4) It can improve the accuracy and reliability of horizontal loading and realize intelligent and digital production; it can improve the level of automation in the horizontal loading process, thereby reducing the workload of workers and shortening the loading cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 A block diagram of a horizontal loading control system provided in an embodiment of the present invention.

[0036] Figure 2 A schematic diagram of an outer state machine provided in an embodiment of the present invention.

[0037] Figure 3 A schematic diagram of an inner state machine provided in an embodiment of the present invention.

[0038] Figure 4 The horizontal loading control process provided by the embodiment of the present invention. DETAILED DESCRIPTION

[0039] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0040] Example 1

[0041] like Figure 1 As shown, this example is a horizontal loading control system, which consists of a handheld box and a host computer for issuing instructions, an embedded loading control unit, an actuator driven by a servo motor, a proximity switch and a pressure sensor.

[0042] The handheld box is connected to the loading control unit through the IO interface and sends instructions to the loading control unit, including "enable", "load", "stop", "speed" and other instructions.

[0043] The host computer communicates with the loading control unit via RS485. The host computer sends control instructions to the loading control unit, including "enable", "load", "stop", "speed" and other instructions. The receiving control unit uploads information such as pressure value, in-place signal status, etc., and provides a human-computer interaction interface;

[0044] The actuator is connected to the loading control unit via the CAN bus and receives instructions from the loading control unit. A servo motor is provided inside the actuator, and the forward and reverse rotation of the servo motor drives the actuator forward and backward. The motor is provided with a brake, and the current position is locked by the brake when stopping.

[0045] The proximity switch includes proximity switch 1 and proximity switch 2. Proximity switch 1 is installed at the front end of the actuator, and proximity switch 2 is installed 20 mm forward of the end of the actuator. It is connected to the loading control unit through IO to feed back the current equipment in-place status to the loading control unit.

[0046] The loading control unit receives instructions from the handheld box and the host computer at the same time, determines the current instruction according to the priority, receives feedback from the proximity switch and pressure sensor, realizes motion protection and automatic stop in place, and is the core part of the entire loading control system.

[0047] The pressure sensors include pressure sensor 1 and pressure sensor 2, both of which are installed at the top of the actuator and connected to the AD interface of the loading control unit so that the loading control unit can obtain pressure, perform over-pressure fault protection and control the actuator to shut down.

[0048] Furthermore, the loading control unit uses a two-layer state machine to decouple emergency matters and routine matters. Figure 2The outer state machine is responsible for handling emergencies, including 9 states: "Not enabled", "Handheld box enabled", "Industrial computer enabled", "Industrial computer enabled switching to handheld box enabled", "Stopped", "Faulty shutdown", "Fault", "Emergency shutdown" and "Emergency stop". These 9 states are used to handle conflicts between handheld box and host computer commands, handle faults, and handle emergency shutdowns. The jump conditions of the state machine constitute the emergency handling logic.

[0049] Furthermore, the outer state machine jump logic is as follows.

[0050] Fault events have the highest priority. When a fault is triggered, as long as it is not currently in the "fault" state, the state machine jumps into the "fault stop" state, and the control system sends an enable command to the actuator to perform shutdown protection. After the shutdown is completed, the state machine enters the "fault" state.

[0051] The emergency stop event has the second highest priority. When the emergency stop is triggered, as long as it is not currently in the "emergency stop" or "fault" state, the state machine jumps into the "emergency stop in progress" state, and the control system sends an enable command to the actuator to perform shutdown protection. After the shutdown is completed, the state machine enters the "emergency stop" state.

[0052] When the state machine is in the "disabled" state, it receives a handheld box enable command and jumps into the "handheld box enabled" state; it receives an industrial computer enable command and jumps into the "industrial computer enabled" state.

[0053] When the state machine is in the "handheld box enabled" state, it receives the handheld box disconnect enable command and jumps into the "stopping" state. After the shutdown is completed, it enters the "disabled" state.

[0054] When the state machine is in the "industrial computer enabled" state, if it receives an industrial computer enable command, it jumps into the "shutdown" state, and enters the "disabled" state after the shutdown is completed; if it receives a handheld box enable command, it jumps into the "switch control" state, and enters the "handheld box enabled" state after the switch is completed.

[0055] When the state machine is in the "fault" state, it will jump back to the "disabled state" only when it receives a fault reset command. It will remain in the "fault state" if it receives other commands.

[0056] When the state machine is in the "Emergency Stop" state, it will jump back to the "Disabled" state only if it receives an emergency stop reset command; if a fault is triggered, it will enter the "Fault" state.

[0057] The inner state machine is responsible for handling routine matters, such as Figure 3 As shown in the figure, there are two states, "idle" and "loading". The jump conditions of the state machine constitute the control logic of the loading process.

[0058] The outer state machine has a higher priority than the inner state machine and can handle urgent matters more quickly.

[0059] Example 2

[0060] Based on the above-mentioned horizontal loading control system, the present application also provides a horizontal loading control method, such as Figure 4 As shown, the following steps are included:

[0061] Step 1: Use the host computer or handheld box to issue the "enable" command;

[0062] Step 2: After the loading control unit receives the "enable", the outer state machine jumps into the enable state, enables the servo motor, and opens the brake.

[0063] Step 3: After enabling, use the handheld box or host computer to issue the loading command.

[0064] Step 4: The loading control unit receives the "loading" command and starts to execute the loading process. The inner state machine jumps into the "loading" state and sends a forward command to the actuator, and the actuator starts to move forward.

[0065] Step 5: During the loading process, the rising edge of proximity switch 1 is triggered, the inner state machine jumps into the "idle state", and the actuator stops.

[0066] Step 6: Manually observe and confirm that the top of the equipment has correctly entered the barrel channel. If there is no interference, use the host computer or handheld box to issue the loading instruction again, execute the loading process, and the actuator continues to move forward;

[0067] Step 7, trigger the rising edge of proximity switch 2, and the forward speed of the actuator is decelerated from the set speed to the first deceleration speed;

[0068] Step 8: After continuing to move forward 10 mm, the forward running speed of the actuator automatically decelerates to the secondary deceleration speed. At this time, the sum F of the pressure values ​​of pressure sensor 1 and pressure sensor 4 is recorded.

[0069] Step nine, the actuator continues to move forward at the secondary deceleration speed, and stops automatically when the sum of the pressure values ​​of the pressure sensor 1 and the pressure sensor 2 increases from F to F+Δ, at which time the loading operation is completed.

[0070] Among them, Δ is the pressure rise threshold, which, together with the first deceleration speed, the second deceleration speed and the set speed, can all be configured through the host computer.

[0071] Furthermore, if excessive pressure occurs during the loading process, the loading control unit will control the actuator to shut down.

[0072] Compared with traditional manual loading, the loading control system and loading control method provided by the present invention adopt a solution based on an embedded real-time system, which can improve loading accuracy and respond to abnormal situations more quickly; they adopt a partially automated control process, which can reduce the labor intensity of workers and shorten the loading time.

[0073] As described above, although the present invention has been shown and described with reference to specific preferred embodiments, it should not be construed as limiting the present invention itself. Various changes may be made to it in form and detail without departing from the spirit and scope of the present invention as defined in the appended claims.

Claims

1. An automatic horizontal loading control system based on an embedded system, characterized in that: It includes a handheld box and a host computer for issuing instructions, an embedded loading control unit, an actuator driven by a servo motor, a proximity switch and a pressure sensor; among which: The handheld box is connected to the loading control unit and sends instructions to the loading control unit; The host computer communicates with the loading control unit, and the host computer sends control instructions to the loading control unit; The actuator is connected to the loading control unit and receives instructions from the loading control unit; Proximity switches are installed at the front and end of the actuator, respectively, and are connected to the loading control unit to feed back the current equipment in-place status to the loading control unit; The pressure sensor is installed on the top of the actuator and connected to the loading control unit, so that the loading control unit can obtain the pressure; The loading control unit receives instructions from the handheld box and the host computer at the same time, determines the current instruction according to the priority, receives feedback from the proximity switch and pressure sensor, and realizes the motion protection of the actuator and automatic stop in place.

2. The automatic horizontal loading control system based on embedded system according to claim 1, characterized in that: The commands include enable, load, stop and speed.

3. The automatic horizontal loading control system based on embedded system according to claim 2 is characterized in that: There is a servo motor inside the actuator, and the forward and reverse rotation of the servo motor drives the actuator forward and backward; there is a brake on the motor, which locks the current position when it stops.

4. The automatic horizontal loading control system based on embedded system according to claim 1, characterized in that: The handheld box is connected to the loading control unit via the IO interface.

5. The automatic horizontal loading control system based on embedded system according to claim 1, characterized in that: The host computer communicates with the loading control unit via RS485.

6. The automatic horizontal loading control system based on embedded system according to claim 1, characterized in that: The actuator is connected to the loading control unit via a CAN bus.

7. The automatic horizontal loading control system based on embedded system according to claim 1, characterized in that: The proximity switch installed at the end of the actuator is 20 mm away from the end edge and is connected to the loading control unit through IO.

8. The automatic horizontal loading control system based on embedded system according to claim 1, characterized in that: The pressure sensors include two and are connected to the AD interface of the loading control unit.

9. The automatic horizontal loading control system based on embedded system according to claim 1, characterized in that: The loading control unit uses an inner and outer two-layer state machine to decouple the emergency and routine matters. The outer state machine is responsible for handling emergency matters, including not enabled, handheld box enabled state, industrial computer enabled, industrial computer enabled switching to handheld box enabled, stopped, faulty shutdown, emergency shutdown and emergency stop state. Based on the priority of the matters, these 9 states are used to handle the conflict between the handheld box and the host computer commands, fault conditions and emergency shutdown matters; the inner state machine is responsible for handling routine matters, including two states: idle and loading.

10. An automatic horizontal loading control method based on the system according to any one of claims 1 to 9, characterized in that: include: Step 1: Use the host computer or handheld box to send the enable command; Step 2: After the loading control unit receives the enable, the outer state machine jumps into the enable state, enables the servo motor, and opens the brake; Step 3: After enabling, use the handheld box or host computer to issue the loading command; Step 4: The loading control unit receives the loading instruction and starts to execute the loading process. The inner state machine jumps into the loading state and sends a forward instruction to the actuator, and the actuator starts to move forward. Step 5: During the loading process, the rising edge of the proximity switch at the front end of the actuator is triggered, the inner state machine jumps into the idle state, and the actuator stops; Step 6: When the top of the equipment correctly enters the barrel channel and there is no interference, use the host computer or handheld box to issue the loading instruction again, execute the loading process, and the actuator continues to move forward; Step 7: Trigger the rising edge of the proximity switch 2 at the end of the actuator, and the forward speed of the actuator is decelerated to the set first-level deceleration speed; Step 8: After continuing to move forward 10 mm, the forward running speed of the actuator is automatically decelerated to the set secondary deceleration speed, and the sum F of the pressure values ​​of the two pressure sensors at this time is obtained; Step nine, the actuator continues to move forward at the secondary deceleration speed, and stops automatically when the sum of the monitored pressure values ​​rises from F to F+Δ, and the loading operation is completed; wherein Δ is the set pressure rise threshold.

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