Full-automatic filling control system suitable for refrigerant steel cylinders of various sizes

Abstract

The invention provides a full-automatic filling control system suitable for refrigerant steel cylinders of various sizes, and the system comprises a steel cylinder positioning module which is used for monitoring and adjusting the positions of the steel cylinders; and the communication module is used for realizing internal data interaction of the system and communication with an upper computer. A traditional manual operation mode is replaced, the efficiency index of the production process and the product qualification rate level are remarkably improved, standardized control over the technological process is achieved, the influence of manual operation errors on the production quality is effectively reduced, and meanwhile productivity output in unit time is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of refrigeration equipment manufacturing and industrial automation, and particularly relates to a full-automatic filling control system suitable for refrigerant cylinders of various sizes. Background Art

[0002] In the traditional mode, when replacing filling bottles with different sizes, manual intervention is often required to adjust the mechanical structure or replace different tooling.

[0003] Manual adjustments require highly specialized skills and extensive experience. They rely on keen observation and precise judgment to fine-tune the filling equipment components to ensure the new bottles perfectly fit the filling process. This approach is subject to human error, potentially impacting product quality stability and production efficiency. Summary of the Invention

[0004] The purpose of the present invention is to construct a fully automatic filling control system suitable for refrigerant cylinders of various sizes.

[0005] The technical solution of the present invention is:

[0006] A fully automatic filling control system adapted for refrigerant cylinders of various sizes, the system comprising:

[0007] Cylinder positioning module, used to monitor and adjust the position of the cylinder;

[0008] The communication module is used to realize data interaction within the system and communication with the host computer.

[0009] Furthermore, the cylinder positioning module includes: X-axis, Y-axis, Z-axis screw modules, a spatial coordinate algorithm model and a photoelectric sensor; wherein,

[0010] The X-axis and Y-axis screw modules are used to drive the cylinder to move and adjust its position to ensure that the center of the cylinder is consistent with the center of the filling scale;

[0011] The Z-axis screw module is used to drive the special filling gun to move;

[0012] The spatial coordinate algorithm model establishes a three-dimensional model database based on the preset cylinder specification parameters and generates a motion instruction set including position correction coefficients;

[0013] Photoelectric sensors are used to detect whether the cylinder is in place.

[0014] Furthermore, the communication module adopts a hybrid communication mode combining Ethernet and RS485, and is connected to the central monitoring system PC through the master station and the switch to achieve data interaction and centralized monitoring.

[0015] Furthermore, the system is equipped with a central monitoring system PC for real-time monitoring of equipment operating status, management of user permissions, recording of filling data and processing of fault alarms.

[0016] Furthermore, the system can process a range of steel cylinder sizes, with the minimum specification being 195mm×195mm×250mm (outer packaging size) and the maximum specification reaching 310mm×310mm×460mm (outer packaging size).

[0017] Furthermore, the core control unit of the system is a PLC controller, which enables the coordinated work of various modules.

[0018] Compared with the prior art, the present invention has the following advantages:

[0019] By replacing traditional manual operation, the technology significantly improves production efficiency and product qualification rates. This technology enables standardized process control, effectively reducing the impact of human error on production quality while increasing production output per unit time.

[0020] This fully automatic filling system has a wide range of applicability and can meet the filling needs of refrigerant cylinders of various sizes.

[0021] With real-time alarm functionality, it can promptly detect abnormal situations and implement safety management. It also supports security permission management to ensure data and operational security. In terms of material management, it can accurately collect material statistics, enable data traceability, and generate reports, providing a detailed basis for production decision-making. Furthermore, it can monitor energy consumption and propose optimization solutions based on data analysis. It also provides strong support for predictive maintenance, foreseeing potential equipment failures, reducing the risk of equipment downtime, and improving overall operational efficiency and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The accompanying drawings illustrate various embodiments generally by way of example and not limitation, and together with the description and claims, serve to explain embodiments of the invention. Where appropriate, the same reference numerals are used throughout the drawings to refer to the same or similar parts. Such embodiments are illustrative and are not intended to be exhaustive or exclusive of the embodiments of the present apparatus or method.

[0023] Figure 1 Shown is a schematic diagram of the system of the present invention;

[0024] Figure 2 A schematic diagram of a communication module of the present invention is shown. DETAILED DESCRIPTION

[0025] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0026] like Figure 1-Figure 2 As shown, the present invention provides a fully automatic filling control system adapted to refrigerant cylinders of various sizes, specifically comprising:

[0027] 1) Cylinder positioning

[0028] The cylinder positioning system primarily consists of X-axis, Y-axis, and Z-axis lead screw modules. The X and Y axes are precisely controlled by stepper motors, while the Z axis is precisely controlled by a servo motor. In addition, a photoelectric sensor is integrated into the system to accurately monitor and adjust the cylinder's position.

[0029] Control process: The system establishes a three-dimensional model database based on the pre-set cylinder specification parameters (including geometric dimensions such as length, width, and height). The PLC controller uses the spatial coordinate algorithm to calculate the theoretical positioning coordinates of the X / Y / Z axes, and simultaneously loads the dimensional deviation compensation program to generate a motion instruction set containing the position correction coefficient, and transmits it to the actuator; when the cylinder enters the work station and triggers the photoelectric sensor, the PLC controller drives the X / Y axes to execute the fine-adjustment positioning program to ensure that the center of the cylinder is consistent with the center of the filling scale, and drives the Z axis to execute the fine-adjustment positioning program to ensure that the cylinder valve nozzle is consistent with the horizontal center of the dedicated filling gun.

[0030] 4)Communication

[0031] The entire production control system utilizes a hybrid communication method combining Ethernet and RS485. Connection to the central control PC is achieved by setting the Ethernet IP address, port number, and protocol. The PC utilizes Ethernet technology to rapidly interact with the configuration system and field device data, collecting, displaying, and processing operational data in real time. Authorized operators can control field device status within the configuration system.

[0032] The present invention focuses on key operating links such as the positioning of cylinders of different sizes that can be controlled by a programmable controller PLC. Each link is closely connected and coordinated to achieve efficient, accurate and stable production goals.

[0033] The cylinder positioning process uses precise positioning devices and advanced technologies to enable the cylinders to reach the designated position accurately and correctly, providing precise basic support for the filling work, thereby ensuring the accuracy and reliability of the entire production process.

[0034] The central monitoring system's PC monitors the operating status of on-site equipment in real time through the configuration system. It manages user permissions and cylinder access authorizations, ensuring strict control of operational permissions at different levels and allowing filling operations to be performed according to authorized levels. The system enables the host computer to control the start and stop of the entire equipment, accurately records equipment operating parameters and filling process data, and stores relevant historical information. Furthermore, the system features fault diagnosis and alarm display capabilities, enabling timely response and resolution of abnormal situations.

[0035] In the entire process, servo motors, stepper motors and other executive components, PLC as the core control unit, sensors and other auxiliary components work together to ensure the efficient, accurate and stable operation of the production process.

[0036] The invention has broad applicability, meeting the filling needs of refrigerant cylinders of various sizes. Specifically, the size range of cylinders it can handle, in terms of length, width, and height, ranges from a minimum of 195mm x 195mm x 250mm (outer packaging dimensions) to a maximum of 310mm x 310mm x 460mm (outer packaging dimensions).

[0037] The above is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field, within the technical scope disclosed by the present invention, can make equivalent replacements or changes based on the technical solutions and inventive concepts of the present invention, which should be covered by the scope of protection of the present invention.

Claims

1. A fully automatic filling control system suitable for refrigerant cylinders of various sizes, characterized by: The system comprises: Cylinder positioning module, used to monitor and adjust the position of the cylinder; The communication module is used to realize data interaction within the system and communication with the host computer.

2. The fully automatic filling control system for refrigerant cylinders of various sizes according to claim 1 is characterized in that: The cylinder positioning module includes: X-axis, Y-axis, Z-axis screw modules, spatial coordinate algorithm model and photoelectric sensor; wherein, The X-axis and Y-axis screw modules are used to drive the cylinder to move and adjust its position to ensure that the center of the cylinder is consistent with the center of the filling scale; The Z-axis screw module is used to drive the special filling gun to move; The spatial coordinate algorithm model establishes a three-dimensional model database based on the preset cylinder specification parameters and generates a motion instruction set including position correction coefficients; Photoelectric sensors are used to detect whether the cylinder is in place.

3. The fully automatic filling control system for refrigerant cylinders of various sizes according to claim 1 is characterized in that: The communication module adopts a hybrid communication mode combining Ethernet and RS485, and is connected to the central monitoring system PC through the master station and the switch to achieve data interaction and centralized monitoring.

4. The fully automatic filling control system for refrigerant cylinders of various sizes according to claim 1 is characterized in that: The system is equipped with a central monitoring system PC for real-time monitoring of equipment operating status, management of user permissions, recording of filling data and processing of fault alarms.

5. The fully automatic filling control system for refrigerant cylinders of various sizes according to claim 1 is characterized in that: The system can process cylinder sizes ranging from a minimum of 195mm×195mm×250mm to a maximum of 310mm×310mm×460mm. The cylinder sizes are the outer packaging sizes.

6. The fully automatic filling control system for refrigerant cylinders of various sizes according to claim 1 is characterized in that: The core control unit of the system is a PLC controller, which enables the coordinated work of various modules.

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