Weighing feedback-based intelligent flow control device and method for shot blasting machine

Abstract

The invention relates to the technical field of automatic control, and discloses an intelligent flow control device and method for a shot blasting machine based on weighing feedback. Comprising a weighing sensing module, a closed-loop control module and a modular structure unit, wherein the weighing sensing module comprises a weighing plate arranged at the tail end of a shot conveying pipeline and a pressure sensor, and the pressure sensor is located at the bottom of the weighing plate and used for collecting force signals generated by shot impact; the closed-loop control module comprises a controller, and a sensor transmitter is arranged between the controller and the pressure sensor. According to the shot blasting machine flow control device, the weighing sensing module is arranged to measure shot material impact force signals in a contact mode, and therefore the problems that most of traditional shot blasting machine flow control devices adopt non-contact flow speed monitoring to indirectly calculate flow and are matched with open-loop control logic and an integrated structure, so that the measurement error is large, and the control stability is insufficient are solved.

Description

Technical Field

[0001] The present invention relates to the field of automatic control technology, and in particular to a shot blasting machine flow intelligent control device and method based on weighing feedback. Background Art

[0002] A shot peening machine is a mechanical device that uses a high-speed stream of shot to impact the surface of a workpiece for purposes such as surface hardening and cleaning. It uses compressed air or centrifugal force to eject shot at high speed onto the workpiece surface, causing plastic deformation and forming residual compressive stress, thereby improving the workpiece's fatigue strength, stress corrosion resistance, and wear resistance. Based on their operating principle, shot peening machines are primarily classified into pneumatic and mechanical types. Pneumatic shot peening machines use compressed air to accelerate the shot and are suitable for processing complex shapes and small batches of workpieces. Mechanical shot peening machines, on the other hand, utilize a high-speed rotating impeller to project the shot, resulting in high production efficiency and suitable for processing large batches of workpieces. In practical applications, shot peening machines are widely used in aerospace, automotive manufacturing, and machining. For example, they are used to harden the surface of components such as aircraft engine blades and automobile crankshafts, as well as for cleaning metal workpieces such as rust removal and descaling. They play a vital role in improving product quality and service life.

[0003] Most traditional shot blasting machine flow control devices use non-contact flow velocity monitoring to indirectly infer flow, combined with open-loop control logic and an integrated structure. Due to the lack of a direct correlation between force, mass and flow, the lack of a real-time feedback mechanism, and the tight coupling of components, large measurement errors and insufficient control stability are caused. Summary of the Invention

[0004] In order to make up for the above shortcomings, the present invention provides an intelligent flow control device and method for shot blasting machines based on weighing feedback, aiming to improve the traditional shot blasting machine flow control devices, which mostly use non-contact flow velocity monitoring to indirectly infer the flow and are combined with open-loop control logic and integrated structure. Due to the lack of a direct correlation between force mass and flow and the lack of a real-time feedback mechanism and tight coupling of components, large measurement errors and insufficient control stability are caused.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a shot blasting machine flow intelligent control device based on weighing feedback, including a weighing sensor module, a closed-loop control module and a modular structural unit: The weighing sensor module includes a weighing plate and a pressure sensor provided at the end of the pellet conveying pipeline. The pressure sensor is located at the bottom of the weighing plate and is used to collect the force signal generated by the impact of the pellets. The closed-loop control module includes a controller, a sensor transmitter is provided between the controller and the pressure sensor, the sensor transmitter is electrically connected to the controller and the pressure sensor through wires, the sensor transmitter is used to receive the signal transmitted by the pressure sensor, and then convert it into a controller signal and transmit it to the controller, the closed-loop control module is electrically connected to the actuator for adjusting the shot flow rate through a control cable to output the adjustment signal; The controller is provided with a filter module inside which filter software is run to eliminate high-frequency noise in the electrical signal; The modular structural unit decouples and connects the weighing sensor module, the actuator and the controller via a standard flange interface or an electrical interface.

[0006] By adopting the above technical solution, a weighing sensor module is set to contact measure the impact force signal of the shot material, and a closed-loop control module is used to calculate the flow based on the force signal and then adjust the opening of the actuator. At the same time, a modular structural unit is used to decouple the functional components, thereby realizing dynamic measurement and closed-loop control of the shot material flow and independent disassembly and assembly of the modules, thereby improving the traditional shot blasting machine flow control device, which mostly adopts non-contact flow velocity monitoring to indirectly calculate the flow and is matched with open-loop control logic and integrated structure. Due to the lack of a direct correlation between force quality and flow and the lack of a real-time feedback mechanism and tight coupling of components, the measurement error is large and the control stability is insufficient.

[0007] Preferably, the weighing sensor module further includes a flexible connection structure, which is arranged between the pressure sensor and the pipeline for isolating vibration, and the signal line of the pressure sensor passes through the housing of the weighing sensor module and is connected to the I / O module of the controller.

[0008] Preferably, the controller of the closed-loop control module has built-in: a force-flow mapping unit and a PID adjustment unit; The force-flow mapping unit establishes a mathematical model based on the momentum theorem , where Q is the flow rate, F1 is the vertical force component collected by the pressure sensor, Δt is the sampling period, and k is the calibration coefficient. The controller converts the force signal into a digital quantity through an A / D converter and then inputs it into the model calculation; The PID (Proportional-Integral-Derivative) regulation unit generates a 4-20 mA current signal according to the deviation between the measured flow rate and the target flow rate, and transmits the signal to the valve positioner of the actuator through the control cable.

[0009] Preferably, the actuator is a diaphragm valve, the valve stem of the diaphragm valve is mechanically connected to the valve positioner, and the valve positioner is an intelligent positioner, which is used to convert the 4-20mA current signal into a mechanical signal, control the air pressure acting on the diaphragm valve, and then control the opening and closing size of the diaphragm valve, and automatically adjust the valve position by detecting the displacement sensor signal, and control the displacement accuracy to ±0.5mm.

[0010] Preferably, the weighing sensor module is connected to the end of the pellet conveying pipeline through a flange, the diaphragm valve is connected in series with the pipeline through upstream and downstream flanges, and the intelligent positioner is fixed to the top of the diaphragm valve by bolts and is electrically connected to the controller; The electrical interfaces of the weighing sensor module, diaphragm valve, intelligent positioner and controller adopt standard aviation plugs, and the mechanical interfaces adopt ISO flange standards.

[0011] The control method of the shot blasting machine flow intelligent control device based on weighing feedback includes the following steps: The vertical component force F1 of the shot impact is collected through the mechanical connection between the weighing plate and the pressure sensor, and the pressure sensor transmits the force signal to the controller through the signal line; The controller is based on a mathematical model Calculate the instantaneous flow rate, where Δt is the sampling period and k is the calibration coefficient; The controller generates a regulating signal according to the flow deviation and transmits it to the actuator through the control cable to adjust the opening; The force signal collected by the sensor is processed by the controller to drive the actuator, and the adjustment result of the actuator is fed back to the sensor to form a closed-loop control process.

[0012] Preferably, before collecting the vertical force component F1, the method further includes: The weighing plate is suspended at the end of the pipeline through a flexible connector, and the pressure sensor is fixed under the weighing plate and connected to the signal conditioning module of the controller through a cable; The sensor transmitter is calibrated in an empty machine. The weighing plate is deformed by loading with standard weights. The controller records the corresponding relationship between F1 and the mass of the weights and generates a calibration curve that is stored in the memory.

[0013] Preferably, the step of adjusting the opening of the actuator includes: The controller samples the force signal at a 50ms cycle, calculates the flow rate, and compares it with the target value. When the deviation exceeds ±3%, the PID algorithm is triggered to generate the adjustment amount. The adjustment amount is converted into a 4-20mA current signal, which is converted into a mechanical signal through a control cable and transmitted to the valve positioner to control the air pressure acting on the diaphragm valve, thereby controlling the opening and closing size of the diaphragm valve, and automatically adjusting the valve position by detecting the displacement sensor signal.

[0014] Preferably, it also includes: The density parameters of the preset steel shot and glass shot materials are stored in the controller. When the material is selected through the human-machine interface, the controller automatically calls the corresponding k value to compensate for the impact force difference; The air pressure sensor is connected to the controller through a signal line. When the air pressure fluctuation exceeds ±5%, the controller adjusts the valve opening according to the pressure-flow correction model.

[0015] Preferably, it also includes: The controller records sensor calibration time and valve actuation times in built-in memory and sends maintenance reminders through the communication interface when the preset threshold is reached. Establish a data connection with the controller via the USB or Ethernet interface to upload new force-flow models or PID parameters to update the control algorithm.

[0016] The present invention has the following beneficial effects: 1. In the present invention, a weighing sensor module is provided to contact-measure the impact force signal of the shot, and a closed-loop control module is used to calculate the flow rate based on the force signal and then adjust the opening of the actuator. At the same time, a modular structural unit is used to decouple the functional components, thereby realizing dynamic measurement and closed-loop control of the shot flow rate and independent assembly and disassembly of the modules. This improves the traditional shot blasting machine flow control device, which mostly uses non-contact flow velocity monitoring to indirectly calculate the flow rate and is combined with open-loop control logic and integrated structure. Due to the lack of a direct correlation between force quality and flow rate and the lack of a real-time feedback mechanism and tight coupling of components, the measurement error is large and the control stability is insufficient.

[0017] 2. In the present invention, the closed-loop control module calculates the flow rate based on the force signal collected by the weighing sensor module and adjusts the opening of the actuator according to the deviation, thereby forming a closed-loop control link of "measurement-calculation-adjustment", thereby improving the traditional control scheme that mostly relies on the open-loop coordination of the mechanical valve flap opening and the electromagnetic signal, and lacks a real-time feedback mechanism, resulting in large flow fluctuations and delayed response.

[0018] 3. In the present invention, the weighing unit, the actuator and the controller are decoupled and connected through a standard interface through a modular structural unit, thereby supporting the rapid disassembly and replacement of single components, thereby improving the problems of traditional imported flow valves that mostly use highly integrated electronic control modules. Since the sensor, controller and actuator are coupled into a single component, it is difficult to locate the fault, the module needs to be replaced as a whole and the maintenance cost is high. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 The figure shows the steps of the control method of the shot blasting machine flow intelligent control device based on weighing feedback proposed by the present invention. DETAILED DESCRIPTION

[0020] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0021] Reference Figure 1 The embodiment of the present invention provides a shot blasting machine flow intelligent control device based on weighing feedback, including a weighing sensor module, a closed-loop control module and a modular structural unit: The weighing sensor module includes a weighing plate and a pressure sensor arranged at the end of the shot conveying pipeline. The pressure sensor is located at the bottom of the weighing plate and is used to collect the force signal generated by the impact of the shot. The closed-loop control module includes a controller, a sensor transmitter is provided between the controller and the pressure sensor, the sensor transmitter is electrically connected to the controller and the pressure sensor through wires, the sensor transmitter is used to receive the signal transmitted by the pressure sensor, and then convert it into a controller signal and transmit it to the controller. The closed-loop control module is electrically connected to the actuator for adjusting the shot flow rate through a control cable to output the adjustment signal; The controller is equipped with a filter module, which runs filter software to eliminate high-frequency noise in the electrical signal. The modular structural unit decouples and connects the weighing sensor module, actuator and controller through a standard flange interface or electrical interface.

[0022] Specifically, through the weighing sensor module: a weighing plate and a bottom pressure sensor are set at the end of the shot conveying pipeline to directly collect the force signal generated by the impact of the shot, provide real-time physical quantity data for flow calculation, and establish a direct relationship between force and flow; a sensor transmitter is set between the controller and the pressure sensor, and is electrically connected to the two through wires, so as to convert the force signal output by the pressure sensor into a standard signal recognizable by the controller, thereby solving the signal compatibility problem between different devices; closed-loop control module: the controller receives the force signal of the pressure sensor through the signal line, and outputs the adjustment signal to the actuator through the control cable after processing by the sensor transmitter, forming a closed-loop control link of "force signal acquisition-flow calculation-execution adjustment", thereby realizing dynamic measurement and precise adjustment of the shot flow; a filtering module is set inside the controller, and the filtering software is run to perform digital filtering on the collected electrical signal to further eliminate high-frequency noise in the signal, and form a multi-level anti-interference system with the hardware filtering circuit; the software algorithm of the filtering software is used for real-time adjustment Adjust the filtering parameters to adapt to the noise characteristics under different working conditions, enhance the system's robustness to random interference, and improve the quality and stability of the force signal; modular structure unit: the weighing sensor module, actuator and controller are decoupled and connected through a standard flange interface or electrical interface. Each module can be independently disassembled and replaced, which improves the convenience of device maintenance. At the same time, the standardized interface ensures the compatibility and interchangeability between modules; by setting up a weighing sensor module to contact measure the impact force signal of the shot material, and using a closed-loop control module to calculate the flow based on the force signal and then adjust the actuator opening, at the same time, the modular structure unit is used to decouple the functional components, thereby realizing dynamic measurement and closed-loop control of the shot material flow and independent disassembly and assembly of the modules, thereby improving the traditional shot blasting machine flow control device. Most of them use non-contact flow velocity monitoring to indirectly infer the flow and are combined with open-loop control logic and integrated structure. Due to the lack of a direct correlation between force quality and flow and the lack of a real-time feedback mechanism and tight coupling of components, large measurement errors and insufficient control stability are caused.

[0023] The weighing sensor module also includes a flexible connection structure, which is arranged between the pressure sensor and the pipeline for isolating vibration. The signal line of the pressure sensor passes through the housing of the weighing sensor module and is connected to the I / O module of the controller.

[0024] Specifically, a flexible connection structure is arranged between the pressure sensor and the pipeline to isolate the interference of pipeline vibration on the weighing plate and the pressure sensor, avoid distortion of force signal acquisition caused by vibration, and play a role of vibration isolation; the signal line of the pressure sensor passes through the casing of the weighing sensor module and is connected to the I / O module of the controller to ensure that the force signal is not affected by structural vibration during transmission, realize stable transmission and acquisition of the signal, and play a role of signal transmission.

[0025] The controller of the closed-loop control module has built-in: force-flow mapping unit and PID regulation unit; The force-flow mapping unit establishes a mathematical model based on the momentum theorem , where Q is the flow rate, F1 is the vertical force component collected by the pressure sensor, Δt is the sampling period, and k is the calibration coefficient. The controller converts the force signal into a digital quantity through an A / D converter and then inputs it into the model calculation; The PID control unit generates a 4-20mA current signal based on the deviation between the measured flow rate and the target flow rate, and transmits it to the valve positioner of the actuator through the control cable.

[0026] Specifically, the force-flow mapping unit establishes a mathematical model based on the momentum theorem, converts the vertical component force F1 collected by the pressure sensor into a digital quantity through A / D, and then calculates the shot flow Q in combination with the sampling period Δt and the calibration coefficient k, thereby realizing accurate mapping from the physical force signal to the process parameters, thereby achieving the purpose of force-flow quantitative conversion; the PID adjustment unit compares the measured flow Q with the target flow in real time, generates a 4-20mA current signal according to the deviation and transmits it to the valve positioner, drives the actuator to adjust the opening, and forms a "measurement-calculation-adjustment" closed-loop control link to ensure that the flow is stable within the target value range, thereby achieving the purpose of dynamic deviation correction; by converting the adjustment amount into a 4-20mA standard current signal, it is compatible with industrial-grade actuators, improves the system's versatility and anti-interference ability, and ensures the reliable transmission of control instructions, thereby achieving the purpose of industrial standard signal adaptation.

[0027] The actuator is a diaphragm valve. The valve stem of the diaphragm valve is mechanically connected to the valve positioner. The valve positioner is an intelligent positioner that converts the 4-20mA current signal into a mechanical signal to control the air pressure acting on the diaphragm valve, thereby controlling the opening and closing size of the diaphragm valve. The valve position is automatically adjusted by detecting the displacement sensor signal, and the displacement accuracy is controlled within ±0.5mm.

[0028] Specifically, the intelligent positioner converts the 4-20mA standard current signal into an air pressure signal, drives the displacement of the diaphragm valve stem, realizes the conversion between electrical control and mechanical action, and thus achieves the purpose of electrical to air signal conversion; the valve stem position is detected in real time by the displacement sensor, forming a closed-loop adjustment of "control signal-execution action-position feedback", ensuring the valve position accuracy of ±0.5mm, thereby achieving the purpose of closed-loop displacement feedback; the precise displacement control of the diaphragm valve directly corresponds to the precise adjustment of the valve opening, realizing precise control of the shot flow rate, improving the stability of the shot peening process, thereby achieving the purpose of high-precision flow regulation; the positioner automatically corrects the valve position deviation through the feedback signal, compensates for errors caused by mechanical wear, air pressure fluctuations and other factors, maintains long-term control accuracy, thereby achieving the purpose of intelligent adaptive compensation.

[0029] The weighing sensor module is connected to the end of the shot conveying pipeline through a flange, the diaphragm valve is connected in series with the pipeline through upstream and downstream flanges, and the intelligent positioner is fixed to the top of the diaphragm valve by bolts and electrically connected to the controller; The electrical interfaces of the weighing sensor module, diaphragm valve, intelligent positioner and controller adopt standard aviation plugs, and the mechanical interfaces adopt ISO flange standards.

[0030] Specifically, the weighing sensor module is connected to the end of the pipeline through a flange, the diaphragm valve is connected to the pipeline in series through upstream and downstream flanges, and the intelligent positioner is fixed to the top of the diaphragm valve with bolts, so that each component can be independently disassembled and installed, which is convenient for equipment maintenance and replacement, thereby achieving the purpose of connection design; the electrical interface adopts a standard aviation plug, and the mechanical interface adopts the ISO flange standard to ensure the compatibility and interchangeability of the connection between the weighing sensor module, diaphragm valve, intelligent positioner and controller, reducing the difficulty of system integration, thereby achieving the purpose of standardized interface adaptation; based on the connection method of the standardized interface, the functional modules such as weighing data acquisition and flow regulation control form a complete system link, ensuring the stable operation of links such as force signal transmission, control instruction execution and opening feedback, thereby achieving the purpose of modular collaborative operation.

[0031] Please see the attached Figure 1 The control method of the shot blasting machine flow intelligent control device based on weighing feedback includes the following steps: The vertical component force F1 of the shot impact is collected through the mechanical connection between the weighing plate and the pressure sensor, and the pressure sensor transmits the force signal to the controller through the signal line; The controller is based on a mathematical model Calculate the instantaneous flow rate, where Δt is the sampling period and k is the calibration coefficient; The controller generates a regulating signal according to the flow deviation and transmits it to the actuator through the control cable to adjust the opening; The force signal collected by the sensor is processed by the controller to drive the actuator, and the adjustment result of the actuator is fed back to the sensor to form a closed-loop control process.

[0032] Specifically, the vertical component force F1 of the shot material impact is collected through the mechanical connection between the weighing plate and the pressure sensor, and transmitted to the controller through the signal line to establish a physical association between the force signal and the flow control, thereby achieving the purpose of physical signal collection and transmission; the controller is based on the momentum theorem mathematical model , converting the collected force signal into an instantaneous flow value, realizing the quantitative mapping from physical quantities to process parameters, thereby achieving the purpose of quantitative conversion of mathematical models; the controller compares the measured flow with the target value to generate an adjustment signal, drives the actuator to move, and forms a closed-loop control through sensor feedback, correcting the flow deviation in real time, thereby achieving the purpose of forming a closed-loop adjustment mechanism; through the continuous process of "acquisition-calculation-adjustment-feedback", the real-time dynamic control of the shot peening machine flow is realized, the process consistency and controllability are improved, thereby achieving the purpose of the stroke dynamic response process.

[0033] Before collecting the vertical force F1, the following steps are also included: The weighing plate is suspended at the end of the pipeline through a flexible connector, and the pressure sensor is fixed under the weighing plate and connected to the signal conditioning module of the controller through a cable; The sensor transmitter is calibrated in an empty machine. The weighing plate is deformed by loading with standard weights. The controller records the corresponding relationship between F1 and the mass of the weights and generates a calibration curve that is stored in the memory.

[0034] Specifically, a flexible connector is used to suspend the weighing plate at the end of the pipeline to isolate the interference of pipeline vibration on the weighing plate and pressure sensor; the pressure sensor is connected to the signal conditioning module of the controller through a cable to ensure stable force signal acquisition and reliable transmission, thereby achieving the purpose of signal interference elimination and transmission; the weighing plate is deformed by loading with standard weights, and the sensor transmitter is calibrated in an empty machine. The controller records the correspondence between the vertical component force F1 and the mass of the weight, generates a calibration curve and stores it in the memory, eliminates the sensor system error, and improves the accuracy of force signal measurement, thereby achieving the purpose of measurement accuracy calibration.

[0035] The steps for adjusting the actuator opening include: The controller samples the force signal at a 50ms cycle, calculates the flow rate, and compares it with the target value. When the deviation exceeds ±3%, the PID algorithm is triggered to generate the adjustment amount. The adjustment amount is converted into a 4-20mA current signal, which is converted into a mechanical signal through a control cable and transmitted to the valve positioner to control the air pressure acting on the diaphragm valve, thereby controlling the opening and closing size of the diaphragm valve. The valve position is automatically adjusted by detecting the displacement sensor signal.

[0036] Specifically, the controller samples the force signal and calculates the flow rate at a 50ms cycle to achieve high-frequency data updates, ensuring rapid capture and response to flow changes, thereby achieving the purpose of high-frequency dynamic response; when the deviation between the measured flow rate and the target value exceeds ±3%, the PID algorithm is triggered to avoid frequent adjustments of the system due to small fluctuations, balancing control accuracy and stability, thereby achieving the purpose of threshold triggering adjustment; the adjustment amount generated by the PID algorithm is converted into a 4-20mA industrial standard current signal, which is transmitted through the control cable to improve anti-interference ability and transmission reliability, thereby achieving the purpose of standardized signal transmission; the intelligent positioner converts the 4-20mA standard current signal into an air pressure signal to drive the diaphragm The valve stem displacement realizes the conversion between electrical control and mechanical action, thereby achieving the purpose of electrical to pneumatic signal conversion; the valve stem position is detected in real time by the displacement sensor, forming a closed-loop adjustment of "control signal-execution action-position feedback", ensuring the valve position accuracy of ±0.5mm, thereby achieving the purpose of closed-loop displacement feedback; the precise displacement control of the diaphragm valve directly corresponds to the precise adjustment of the valve opening, realizing precise control of the shot flow rate, improving the stability of the shot peening process, thereby achieving the purpose of high-precision flow regulation; the positioner automatically corrects the valve position deviation through the feedback signal, compensates for errors caused by factors such as mechanical wear and air pressure fluctuations, maintains long-term control accuracy, thereby achieving the purpose of intelligent adaptive compensation.

[0037] Also includes: The density parameters of the preset steel shot and glass shot materials are stored in the controller. When the material is selected through the human-machine interface, the controller automatically calls the corresponding k value to compensate for the impact force difference; The air pressure sensor is connected to the controller through a signal line. When the air pressure fluctuation exceeds ±5%, the controller adjusts the valve opening according to the pressure-flow correction model.

[0038] Specifically, the density parameters of different materials such as steel shots and glass shots are preset, and the corresponding calibration coefficient k is automatically called when the material is selected through the human-machine interface to compensate for the impact force changes caused by density differences, ensure the accuracy of the flow calculation model, and thus achieve the purpose of material adaptability compensation; the air path pressure sensor monitors the air pressure changes in real time. When the fluctuation exceeds ±5%, the controller dynamically adjusts the valve opening based on the pressure-flow correction model to offset the impact of air pressure fluctuations on the shot flow rate and maintain flow stability, thereby achieving the purpose of air pressure fluctuation correction; through the preset material parameters and real-time monitoring of air pressure, the full-process adaptive control of force signal acquisition, flow calculation, and execution adjustment is realized, and the system's robustness to changes in process conditions is enhanced, thereby achieving the purpose of multi-parameter collaborative control.

[0039] Also includes: The controller records sensor calibration time and valve actuation times in built-in memory and sends maintenance reminders through the communication interface when the preset threshold is reached. Establish a data connection with the controller via the USB or Ethernet interface to upload new force-flow models or PID parameters to update the control algorithm.

[0040] Specifically, the controller's built-in memory records sensor calibration time and valve action data. Through preset threshold settings, when the data reaches the threshold, a maintenance reminder is sent through the communication interface to achieve real-time monitoring of equipment status and preventive maintenance, avoid sudden failures, and thus achieve the purpose of equipment status monitoring and early warning; establish a data connection with the controller through the USB or Ethernet interface, support uploading new force flow models or PID parameters, realize remote update of the control algorithm, meet the needs of different working conditions, improve system adaptability and control accuracy, and thus achieve the purpose of flexible algorithm upgrade.

[0041] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. The intelligent flow control device of shot blasting machine based on weighing feedback is characterized in that: Including weighing sensor module, closed-loop control module and modular structure unit: The weighing sensor module includes a weighing plate and a pressure sensor provided at the end of the pellet conveying pipeline. The pressure sensor is located at the bottom of the weighing plate and is used to collect the force signal generated by the impact of the pellets. The closed-loop control module includes a controller, a sensor transmitter is provided between the controller and the pressure sensor, the sensor transmitter is electrically connected to the controller and the pressure sensor through wires, the sensor transmitter is used to receive the signal transmitted by the pressure sensor, and then convert it into a controller signal and transmit it to the controller, the closed-loop control module is electrically connected to the actuator for adjusting the shot flow rate through a control cable to output the adjustment signal; The controller is provided with a filter module inside which filter software is run to eliminate high-frequency noise in the electrical signal; The modular structural unit decouples and connects the weighing sensor module, the actuator and the controller via a standard flange interface or an electrical interface.

2. The shot blasting machine flow intelligent control device based on weighing feedback according to claim 1 is characterized in that: The weighing sensor module also includes a flexible connection structure, which is arranged between the pressure sensor and the pipeline for isolating vibration. The signal line of the pressure sensor passes through the housing of the weighing sensor module and is connected to the I / O module of the controller.

3. The shot blasting machine flow intelligent control device based on weighing feedback according to claim 2 is characterized in that: The controller of the closed-loop control module has built-in: a force-flow mapping unit and a PID adjustment unit; The force-flow mapping unit establishes a mathematical model based on the momentum theorem , where Q is the flow rate, F1 is the vertical force component collected by the pressure sensor, Δt is the sampling period, and k is the calibration coefficient. The controller converts the force signal into a digital quantity through an A / D converter and then inputs it into the model calculation; The PID adjustment unit generates a 4-20 mA current signal according to the deviation between the measured flow rate and the target flow rate, and transmits the signal to the valve positioner of the actuator through the control cable.

4. The shot blasting machine flow intelligent control device based on weighing feedback according to claim 3 is characterized in that: The actuator is a diaphragm valve, the valve stem of the diaphragm valve is mechanically connected to the valve positioner, and the valve positioner is an intelligent positioner, which is used to convert a 4-20mA current signal into a mechanical signal, control the air pressure acting on the diaphragm valve, and then control the opening and closing size of the diaphragm valve. By detecting the displacement sensor signal, the valve position is automatically adjusted, and the displacement accuracy is controlled within ±0.5mm.

5. The shot blasting machine flow intelligent control device based on weighing feedback according to claim 4 is characterized in that: The weighing sensor module is connected to the end of the pellet conveying pipeline through a flange, the diaphragm valve is connected in series with the pipeline through upstream and downstream flanges, and the intelligent positioner is fixed to the top of the diaphragm valve by bolts and is electrically connected to the controller; The electrical interfaces of the weighing sensor module, diaphragm valve, intelligent positioner and controller adopt standard aviation plugs, and the mechanical interfaces adopt ISO flange standards.

6. A control method for a shot blasting machine flow intelligent control device based on weighing feedback, applied to the shot blasting machine flow intelligent control device based on weighing feedback according to any one of claims 1 to 5, characterized in that: The following steps are involved: The vertical component force F1 of the shot impact is collected through the mechanical connection between the weighing plate and the pressure sensor, and the pressure sensor transmits the force signal to the controller through the signal line; The controller is based on a mathematical model Calculate the instantaneous flow rate, where Δt is the sampling period and k is the calibration coefficient; The controller generates a regulating signal according to the flow deviation and transmits it to the actuator through the control cable to adjust the opening; The force signal collected by the sensor is processed by the controller to drive the actuator, and the adjustment result of the actuator is fed back to the sensor to form a closed-loop control process.

7. The control method of the shot blasting machine flow intelligent control device based on weighing feedback according to claim 6 is characterized in that: Before collecting the vertical force component F1, the method further includes: The weighing plate is suspended at the end of the pipeline through a flexible connector, and the pressure sensor is fixed under the weighing plate and connected to the signal conditioning module of the controller through a cable; The sensor transmitter is calibrated in an empty machine. The weighing plate is deformed by loading with standard weights. The controller records the corresponding relationship between F1 and the mass of the weights and generates a calibration curve that is stored in the memory.

8. The control method of the shot blasting machine flow intelligent control device based on weighing feedback according to claim 6 is characterized in that: The step of adjusting the opening of the actuator includes: The controller samples the force signal at a 50ms cycle, calculates the flow rate, and compares it with the target value. When the deviation exceeds ±3%, the PID algorithm is triggered to generate the adjustment amount. The adjustment amount is converted into a 4-20mA current signal, which is converted into a mechanical signal through a control cable and transmitted to the valve positioner to control the air pressure acting on the diaphragm valve, thereby controlling the opening and closing size of the diaphragm valve, and automatically adjusting the valve position by detecting the displacement sensor signal.

9. The control method of the shot blasting machine flow intelligent control device based on weighing feedback according to claim 6, characterized in that: Also includes: The density parameters of the preset steel shot and glass shot materials are stored in the controller. When the material is selected through the human-machine interface, the controller automatically calls the corresponding k value to compensate for the impact force difference; The air pressure sensor is connected to the controller through a signal line. When the air pressure fluctuation exceeds ±5%, the controller adjusts the valve opening according to the pressure-flow correction model.

10. The control method of the shot blasting machine flow intelligent control device based on weighing feedback according to claim 6, characterized in that: Also includes: The controller records sensor calibration time and valve actuation times in built-in memory and sends maintenance reminders through the communication interface when the preset threshold is reached. Establish a data connection with the controller via the USB or Ethernet interface to upload new force-flow models or PID parameters to update the control algorithm.

Images