Intelligent speed regulation control system and method for large extruder

Abstract

The intelligent speed regulation control system comprises a variable pump control unit, an extrusion oil cylinder, a displacement sensor, a PLC (Programmable Logic Controller) control system and an HMI (Human Machine Interface), and the movable end of the extrusion oil cylinder is connected with an extrusion rod; the variable pump control unit is communicated with the extrusion oil cylinder, the displacement sensor is arranged on the fixed beam and used for detecting and recording the position of an extrusion rod in real time, an extrusion die model and an extrusion speed process database are stored in the HMI, and the variable pump control unit, the displacement sensor and the HMI are all in electric signal connection with the PLC control system. According to the invention, the PLC control system monitors the feedback value of the opening of the variable pump and the data change of the displacement of the extrusion rod in real time, and adjusts the speed change in the extrusion process in real time, so that the extrusion speed change range and the opening change of the servo proportional valve always maintain a dynamic balance, and the intelligent degree and the adaptive degree are high; and the labor cost and the production cost are greatly reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of electrical control of aluminum extruder equipment for metallurgical equipment, and in particular relates to an intelligent speed regulation control system and method for a large extruder. Background Art

[0002] During the extrusion production process of the aluminum extruder, the extrusion speed needs to be adjusted according to the state of the extrusion force and the extrusion temperature in order to produce products with high quality standards.

[0003] Currently, the main method for speed regulation during the extrusion process is manual input on the HMI touch screen. In actual production, the increase or decrease of extrusion speed must be input gradually. Manual speed adjustment places strict demands on production workers to avoid extrusion speed fluctuations caused by misoperation or large jumps in input values, which can cause aluminum extrusion products to "bloom" and extrusion rings. This method not only consumes manpower and material resources and increases labor costs, but also poses certain safety risks. Summary of the Invention

[0004] The purpose of the present invention is to provide an intelligent speed control system for a large extruder to overcome the above-mentioned technical problems existing in the prior art.

[0005] Another object of the present invention is to provide an intelligent speed control method for a large extruder, which can adjust the speed change during the extrusion process in real time to ensure smooth extrusion.

[0006] To this end, the technical solutions provided by the present invention are as follows: An intelligent speed control system for a large extruder, comprising a variable pump control unit, an extrusion cylinder, a displacement sensor, a PLC control system and an HMI human-machine interface, wherein the movable end of the extrusion cylinder is connected to the extrusion rod; The variable pump control unit is connected to the extrusion cylinder, the displacement sensor is arranged on the fixed beam, and the displacement sensor is used to detect and record the position of the extrusion rod in real time. The HMI human-machine interface stores the extrusion die model and extrusion speed process database. The variable pump control unit, displacement sensor and HMI human-machine interface are all connected to the PLC control system electrical signal. The variable pump control unit includes a variable pump and a variable pump amplifier board. There are multiple variable pumps and variable pump amplifier boards and they correspond one to one. The variable pumps are equipped with servo proportional valves. The servo proportional valves and variable pump amplifier boards are installed on the variable pumps. The servo proportional valves and variable pump amplifier boards are connected to the PLC control system electrical signals.

[0007] The extrusion cylinder includes a main cylinder and a side cylinder. The main cylinder is connected to the variable pump through the main cylinder large cavity liquid inlet valve. A main cylinder isolation valve and a main cylinder pressure sensor are provided on the pipeline between the main cylinder and the main cylinder large cavity liquid inlet valve. The side cylinder is connected to the variable pump through the side cylinder small cavity liquid inlet valve. The main cylinder is connected to the hydraulic station through the main cylinder large cavity liquid discharge valve. The side cylinder is connected to the hydraulic station through the side cylinder small cavity liquid discharge valve.

[0008] The PLC control system includes a PLC controller, a digital output module, an analog input module and an analog output module.

[0009] The die model includes the correspondence between the types of alloy elements of the product to be extruded and the shape of the profile.

[0010] The extrusion process database includes extrusion breakthrough pressure, extrusion pressure and extrusion discharge speed.

[0011] The displacement sensor is a magnetostrictive displacement sensor, which consists of an induction magnet and a positioning magnet. The positioning magnet is sleeved on the induction magnet, and the induction magnet is fixed on the fixed beam. The variable pump drives the extrusion rod to move back and forth by allowing hydraulic oil to flow in and out of the main cylinder and the side cylinder.

[0012] The HMI human-machine interface and the PLC controller exchange data via TCP / IP communication.

[0013] The servo proportional valve is connected to the digital output module by signal, the variable pump amplifier board is connected to the analog output module by signal, and the displacement sensor is connected to the analog input module by signal.

[0014] A large-scale extruder intelligent speed control method comprises the following steps: Step 1) The material properties of the current batch of profiles and the selected mold type are set on the HMI. The PLC controller in the PLC control system intelligently selects the optimal extrusion speed and extrusion pressure for the profile and the optimal opening value Q of the pump head of each variable pump based on the extrusion speed model parameters stored in the HMI. Step 2) When extrusion production starts, the PLC controller adjusts the variable pump opening by controlling the variable pump amplifier board, and monitors and records in real time whether the opening value of each variable pump reaches the optimal opening value Q of the pump head; The PLC controller monitors the displacement sensor value in real time and obtains the real-time extrusion speed value V ; Step 3) When the extrusion speed V When the required extrusion speed value is outside the range, the PLC controller dynamically closes the extrusion speed value by adjusting the opening degree of the corresponding servo proportional valve in real time until the extrusion speed requirement is met.

[0015] The beneficial effects of the present invention are: The large-scale extruder intelligent speed control system provided by the present invention monitors the data changes of the variable pump opening feedback value and the extrusion rod displacement in real time through the PLC control system, and adjusts the speed changes during the extrusion process in real time, so that the extrusion speed change range and the opening change of the servo proportional valve always maintain a dynamic balance. It has a high degree of intelligence and adaptability, realizes intelligent matching of the extrusion speed of the profile of the extrusion production line, improves the production efficiency of the extrusion production line and the performance quality of the profile products, and greatly reduces labor and production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a principle block diagram of the system of the present invention; Figure 2 It is the principle block diagram of the PLC control system; Figure 3 It is a flow chart of the method of the present invention.

[0017] In the figure: 1. Variable pump control unit; 2. Variable pump; 3. Servo proportional valve; 4. Variable pump amplifier board; 5. Master cylinder; 6. Side cylinder; 7. PLC control system; 8. HMI human-machine interface; 9. Displacement sensor; 10. Master cylinder pressure sensor; 11. Master cylinder isolation valve; 12. Master cylinder large cavity inlet valve; 13. Master cylinder large cavity drain valve; 14. Side cylinder small cavity drain valve; 15. Side cylinder small cavity inlet valve; 16. Extrusion rod; 17. Movable end. DETAILED DESCRIPTION

[0018] The following describes the embodiments of the present invention through specific embodiments. Those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0019] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided so as to provide a thorough and complete disclosure of the present invention and fully convey the scope of the present invention to those skilled in the art. The terminology used in the exemplary embodiments shown in the accompanying drawings is not intended to limit the present invention. In the accompanying drawings, identical elements are denoted by the same reference numerals.

[0020] Unless otherwise specified, the terms used herein (including technical and scientific terms) have the meanings commonly understood by those skilled in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have meanings consistent with the context of their relevant fields and should not be interpreted as idealized or overly formal.

[0021] Example 1 The present invention provides an intelligent speed control system for a large extruder, comprising a variable pump control unit 1, an extrusion cylinder, a displacement sensor 9, a PLC control system 7 and an HMI human-machine interface 8, wherein the movable end 17 of the extrusion cylinder is connected to the extrusion rod 16; The variable pump control unit 1 is connected to the extrusion cylinder, the displacement sensor 9 is arranged on the fixed beam, and the displacement sensor 9 is used to detect and record the position of the extrusion rod in real time. The HMI human-machine interface 8 stores the extrusion die model and extrusion speed process database. The variable pump control unit 1, displacement sensor 9 and HMI human-machine interface 8 are all electrically connected to the PLC control system 7. The large-scale extruder intelligent speed control system provided by the present invention monitors the data changes of the opening feedback value of the variable pump 2 and the displacement of the extrusion rod in real time through the PLC control system 7, and can adjust the speed changes during the extrusion process in real time.

[0022] Example 2 Based on Example 1, this embodiment provides an intelligent speed control system for a large extruder, such as Figure 1 As shown, the variable pump control unit 1 includes a variable pump 2 and a variable pump amplifier board 4. The variable pump 2 and the variable pump amplifier board 4 are multiple and one-to-one corresponding. The variable pump 2 is equipped with a servo proportional valve 3. The servo proportional valve 3 and the variable pump amplifier board 4 are both installed on the variable pump 2. The servo proportional valve 3 and the variable pump amplifier board 4 are both connected to the PLC control system 7 with electrical signals.

[0023] The variable displacement pump is a pump with variable displacement and is a commercially available product. The servo proportional valve 3 and the variable displacement pump amplifier board 4 are both existing products.

[0024] When extrusion production starts, the PLC controller monitors and records the opening value of each variable pump 2 in real time and controls the variable pump amplifier board 4 in real time to make the opening of the variable pump 2 reach the optimal required value. Each variable pump 2 dynamically adjusts the output value of the variable pump amplifier board 4 in real time according to the change of its opening value feedback value to meet the opening requirements of the variable pump 2.

[0025] Example 3 On the basis of Example 1, this embodiment provides an intelligent speed control system for a large extruder, wherein the extrusion cylinder includes a main cylinder 5 and a side cylinder 6, the main cylinder 5 is connected to the variable pump 2 through the main cylinder large cavity liquid inlet valve 12, a main cylinder isolation valve 11 and a main cylinder pressure sensor 10 are provided on the pipeline between the main cylinder 5 and the main cylinder large cavity liquid inlet valve 12, the side cylinder 6 is connected to the variable pump 2 through the side cylinder small cavity liquid inlet valve 15, the main cylinder 5 is connected to the hydraulic station through the main cylinder large cavity liquid discharge valve 13, and the side cylinder 6 is connected to the hydraulic station through the side cylinder small cavity liquid discharge valve 14.

[0026] like Figure 1As shown, the master cylinder isolation valve 11 is used to prevent the hydraulic oil from flowing back; the master cylinder pressure sensor 10 is used to measure the pressure of the master cylinder 5 and convert the pressure into a digital signal and transmit it to the PLC control system 7.

[0027] The main cylinder large cavity inlet valve 12, the main cylinder isolation valve 11, the side cylinder small cavity inlet valve 15, the main cylinder large cavity discharge valve 13, and the side cylinder small cavity discharge valve 14 are all existing valves. The main cylinder pressure sensor 10 is a sensor commonly used in industry and is a well-known technology.

[0028] Example 4 Based on Example 1, this embodiment provides an intelligent speed control system for a large extruder, such as Figure 2 As shown, the PLC control system 7 includes a PLC controller, a digital output module, an analog input module and an analog output module.

[0029] Each variable pump is equipped with a pump head valve, which is connected to the main cylinder's fluid inlet via a pipeline. The pump head valve controls flow. The pump head valve is connected to a digital output module. The servo proportional valve 3 is connected to an analog output module. The variable pump amplifier board 4 communicates with the PLC controller via TCP / IP. The displacement sensor 9 and the main cylinder pressure sensor 10 are both connected to the analog input module.

[0030] Example 5 On the basis of Example 1, this embodiment provides an intelligent speed control system for a large extruder, wherein the die model includes a correspondence between the types of alloy elements of the product to be extruded and the shape of the profile.

[0031] The extrusion process database includes extrusion breakthrough pressure, extrusion pressure and extrusion discharge speed. The HMI human-machine interface 8 and the PLC controller exchange data via TCP / IP communication.

[0032] Example 6 Based on Example 1, this embodiment provides an intelligent speed control system for a large extruder. The displacement sensor 9 is a magnetostrictive displacement sensor, which consists of an induction magnet and a positioning magnet. The positioning magnet is sleeved on the induction magnet, and the induction magnet is fixed on the fixed beam. The variable pump 2 drives the extrusion rod to move back and forth by hydraulic oil entering and exiting the main cylinder 5 and the side cylinder 6.

[0033] The displacement sensor 9 detects and records the current position of the extrusion rod in real time, with the end face of the extruder die as the zero point.

[0034] Example 7 This embodiment provides a large-scale extruder intelligent speed control method, such as Figure 3 As shown, the following steps are included: Step 1) The material properties of the current batch of profiles and the selected mold type are set on the HMI human-machine interface 8. The PLC controller in the PLC control system 7 intelligently selects the optimal extrusion speed and extrusion pressure for the profiles and the optimal pump head opening value Q of each variable pump 2 based on the extrusion speed model parameters stored in the HMI human-machine interface 8; Step 2) When extrusion production starts, the PLC controller adjusts the opening of the variable pump 2 by controlling the variable pump amplifier board 4, and monitors and records in real time whether the opening value of each variable pump 2 reaches the optimal opening value Q of the pump head; The PLC controller monitors the value of the displacement sensor 9 in real time and obtains the real-time extrusion speed value V ; Step 3) When the extrusion speed V When the required extrusion speed value is outside the range, the PLC controller dynamically closes the extrusion speed value by adjusting the opening degree of the corresponding servo proportional valve 3 in real time until the extrusion speed requirement is met.

[0035] The large-scale extruder intelligent speed control system provided by the present invention monitors the data changes of the opening feedback value of the variable pump 2 and the displacement of the extrusion rod in real time through the PLC control system 7, and adjusts the speed changes during the extrusion process in real time, so that the speed change range of the extrusion and the opening change of the servo proportional valve 3 always maintain a dynamic balance. It has a high degree of intelligence and adaptability, realizes intelligent matching of the extrusion speed of the profile of the extrusion production line, improves the production efficiency of the extrusion production line and the performance quality of the profile products, and greatly reduces labor and production costs.

[0036] The above examples are merely illustrative of the present invention and do not limit the scope of protection of the present invention. Any design that is identical or similar to the present invention falls within the scope of protection of the present invention.

Claims

1. An intelligent speed control system for a large extruder, characterized by: It includes a variable pump control unit, an extrusion oil cylinder, a displacement sensor, a PLC control system and an HMI human-machine interface, wherein the movable end of the extrusion oil cylinder is connected to the extrusion rod; The variable pump control unit is connected to the extrusion cylinder, the displacement sensor is arranged on the fixed beam, and the displacement sensor is used to detect and record the position of the extrusion rod in real time. The HMI human-machine interface stores the extrusion die model and extrusion speed process database. The variable pump control unit, displacement sensor and HMI human-machine interface are all connected to the PLC control system electrical signal.

2. The intelligent speed control system for a large extruder according to claim 1, characterized in that: The variable pump control unit includes a variable pump and a variable pump amplifier board. There are multiple variable pumps and variable pump amplifier boards and they correspond one to one. The variable pumps are equipped with servo proportional valves. The servo proportional valves and variable pump amplifier boards are installed on the variable pumps. The servo proportional valves and variable pump amplifier boards are connected to the PLC control system 7 with electrical signals.

3. The intelligent speed control system for a large extruder according to claim 2, characterized in that: The extrusion cylinder includes a main cylinder and a side cylinder. The main cylinder is connected to the variable pump through the main cylinder large cavity liquid inlet valve. A main cylinder isolation valve and a main cylinder pressure sensor are provided on the pipeline between the main cylinder and the main cylinder large cavity liquid inlet valve. The side cylinder is connected to the variable pump through the side cylinder small cavity liquid inlet valve. The main cylinder is connected to the hydraulic station through the main cylinder large cavity liquid discharge valve. The side cylinder is connected to the hydraulic station through the side cylinder small cavity liquid discharge valve.

4. The intelligent speed control system for a large extruder according to claim 2, characterized in that: The PLC control system includes a PLC controller, a digital output module, an analog input module and an analog output module.

5. The intelligent speed control system for a large extruder according to claim 1 is characterized in that: The die model includes the correspondence between the types of alloy elements of the product to be extruded and the shape of the profile.

6. The intelligent speed control system for a large extruder according to claim 1, characterized in that: The extrusion process database includes extrusion breakthrough pressure, extrusion pressure and extrusion discharge speed.

7. The intelligent speed control system for a large extruder according to claim 3 is characterized in that: The displacement sensor is a magnetostrictive displacement sensor, which consists of an induction magnet and a positioning magnet. The positioning magnet is sleeved on the induction magnet, and the induction magnet is fixed on the fixed beam. The variable pump drives the extrusion rod to move back and forth by allowing hydraulic oil to flow in and out of the main cylinder and the side cylinder.

8. The intelligent speed control system for a large extruder according to claim 4, characterized in that: The HMI human-machine interface and the PLC controller exchange data via TCP / IP communication.

9. The intelligent speed control system for a large extruder according to claim 4, characterized in that: The servo proportional valve is connected to the digital output module by signal, the variable pump amplifier board is connected to the analog output module by signal, and the displacement sensor is connected to the analog input module by signal.

10. A large-scale extruder intelligent speed control method, using the large-scale extruder intelligent speed control system according to claim 1, characterized in that: The following steps are involved: Step 1) The material properties of the current batch of profiles and the selected mold type are set on the HMI. The PLC controller in the PLC control system intelligently selects the optimal extrusion speed and extrusion pressure for the profile and the optimal opening value Q of the pump head of each variable pump based on the extrusion speed model parameters stored in the HMI. Step 2) When extrusion production starts, the PLC controller adjusts the variable pump opening by controlling the variable pump amplifier board, and monitors and records in real time whether the opening value of each variable pump reaches the optimal opening value Q of the pump head; The PLC controller monitors the displacement sensor value in real time and obtains the real-time extrusion speed value V ; Step 3) When the extrusion speed V When the required extrusion speed value is outside the range, the PLC controller dynamically closes the extrusion speed value by adjusting the opening degree of the corresponding servo proportional valve in real time until the extrusion speed requirement is met.

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