Improved and optimized feeding and shifting system of straightening machine

Abstract

The invention discloses an improved and optimized feeding and shifting system for a straightening machine, which comprises a shifting arm used for transferring a steel plate from an initial position to a working area of the straightening machine, and an S-shaped cooling channel is designed in the shifting arm and used for circulation of cooling liquid; the cooling liquid circulating unit is used for inputting cooling liquid into the snakelike cooling channel of the material stirring arm through a connecting pipe; the sensor unit is used for collecting steel plate surface contact pressure data and material stirring arm abrasion depth data; the data integration and analysis unit is used for collecting monitoring data of the laser displacement sensor and the pressure sensor; the actuator is used for controlling an angle device on the material stirring arm to adjust the angle of the material stirring arm according to the analysis result of the data integration and analysis unit; the device has the beneficial effects that the abrasion loss and the abrasion rate are calculated, the inclination angle of the material stirring arm is automatically adjusted based on abrasion data, the alarm maintenance function is set, and the manual inspection and adjustment workload is reduced.

Description

Technical Field

[0001] The invention relates to the field of straightening machine feeding systems, in particular to a straightening machine feeding and diverting improvement and optimization system. Background Art

[0002] In industries like steel and machinery manufacturing, straighteners are key equipment for sheet metal processing, and their performance directly impacts product quality and production efficiency. The straightener's loading and dispensing system, the core link in material transportation, is responsible for precisely transporting steel plates and other materials from their initial position to the straightening work area. However, traditional loading and dispensing systems suffer from numerous technical bottlenecks: These include poor product quality and irrational dispensing arm design. For example, fixed tilt angles and a lack of surface protection can easily scratch the steel plate surface during the dispensing process, resulting in product appearance flaws and quality defects. Furthermore, heat accumulation is a prominent issue. Prolonged, high-intensity operation raises the temperature of the dispensing arm, causing aging of the rubber protective layer and thermal deformation of components, further exacerbating the risk of surface damage. Furthermore, the system suffers from poor adaptability and low intelligence levels. It lacks real-time wear monitoring and automatic adjustment mechanisms, relying on manual inspections to detect equipment anomalies and failing to promptly address performance degradation caused by wear, which can easily lead to production interruptions and safety hazards. These issues severely restrict the production efficiency and economic benefits of straighteners, necessitating an urgent need for system upgrades and optimization through technological innovation. Summary of the Invention

[0003] The purpose of the present invention is to solve the above-mentioned problems, and therefore proposes an improved and optimized system for feeding and shifting materials of a straightening machine.

[0004] The purpose of the present invention can be achieved through the following technical solutions: A straightening machine feeding and digging improvement and optimization system, comprising:

[0005] The diverter arm is used to transfer the steel plate from the initial position to the working area of ​​the straightening machine to complete the loading task. The diverter arm is designed with a serpentine cooling channel inside. The serpentine cooling channel is used for the circulation of coolant to absorb the heat generated by the diverter arm when working;

[0006] The coolant circulation unit is used to input coolant into the serpentine cooling channel of the diverter arm through the connecting pipe;

[0007] The sensor unit is used to collect the contact pressure data of the steel plate surface and the wear depth data of the feed arm;

[0008] The data integration and analysis unit is used to collect monitoring data from the laser displacement sensor and the pressure sensor, analyze and process the data, calculate the wear amount and wear rate of the material diverter arm, and analyze the pressure data to trigger the angle adjustment program according to the analysis results;

[0009] The actuator is used to control the angle device on the material diverter arm to adjust the angle of the material diverter arm according to the analysis results of the data integration and analysis unit.

[0010] Furthermore, the coolant circulation unit is composed of a coolant storage tank, a circulation pump, a temperature sensor, an electric control valve and a cooling control unit. The coolant storage tank is used to store coolant, the circulation pump is used to drive the coolant to circulate in the cooling channel, and the temperature sensor is installed at the contact point between the material feeding arm and the material, the bearing connection point and the motor drive end position of the material feeding arm, and is used to monitor the temperature in real time and transmit the data to the cooling control unit. The cooling control unit is used to generate a control signal according to the temperature parameter, and the electric control valve adjusts the flow of the coolant according to the control signal generated by the cooling control unit.

[0011] Furthermore, the sensor unit consists of a laser displacement sensor and a pressure sensor. The laser displacement sensor is arranged at the working surface position where the material feeding arm is in direct contact with the steel plate to monitor the wear depth. The pressure sensor is embedded and installed at the center position of the working surface to collect contact pressure data with the surface of the steel plate.

[0012] Furthermore, the calculation of the wear amount is as follows: by establishing a three-dimensional model of the material tapping arm in the initial state as a benchmark, the point cloud data collected in real time by the laser displacement sensor is compared with the benchmark model, and the least squares method is used to fit the surface to calculate the average distance difference between the current contour and the initial contour in the vertical direction. This difference is the real-time wear amount of the material tapping arm.

[0013] Furthermore, the wear rate is calculated as follows: with a fixed time interval as a period, the wear amount data in each period is recorded, the difference in wear amount between two adjacent periods is divided by the time interval to obtain the wear rate in the time period, and the wear rate data of multiple periods are subjected to sliding average processing to reduce the error caused by data fluctuations and obtain the wear rate trend.

[0014] Furthermore, a rubber protective layer is provided on the contact surface of the material-diverting arm, and the rubber protective layer is used to reduce damage to the surface of the steel plate during the material-diverting process.

[0015] Furthermore, the generation process of the adjustment signal is: setting the coolant flow and circulation speed parameters corresponding to different temperature intervals; when the temperature is in the normal range, controlling the electric control valve to make the coolant flow at a predetermined flow and circulation speed to maintain basic heat dissipation; when the temperature approaches a preset threshold, increasing the coolant flow, increasing the circulation speed, and enhancing heat dissipation; once the temperature of the material feeding arm exceeds the preset threshold, the PID control algorithm is immediately used to dynamically adjust the electric control valve and the circulation pump speed according to the deviation between the real-time temperature and the target temperature to ensure that the temperature of the material feeding arm drops rapidly and stabilizes within the set range.

[0016] Furthermore, the angle adjustment program specifically includes: automatically adjusting the tilt angle of the feeder arm according to the wear monitoring data; when the calculated wear exceeds a preset threshold, or the wear rate exceeds the set rate threshold for three consecutive cycles, the situation is defined as severe wear, and the automatic angle adjustment device is activated. According to the pre-established wear amount and angle compensation mathematical model, the wear amount is calculated and compensated in real time. At the same time, the system generates an early warning message to prompt maintenance personnel to inspect and replace the severely worn feeder arm;

[0017] For pressure data analysis, pressure fluctuations will be monitored in real time. When the pressure value exceeds the set range, the pressure adjustment program will be automatically triggered. Through the fuzzy control algorithm, combined with the current steel plate thickness and material hardness parameters, the fine-tuning amount of the feed arm angle will be calculated.

[0018] Furthermore, the coolant is an ethylene glycol aqueous solution, which is used to transfer heat from the diverter arm.

[0019] Furthermore, the diverter arm is connected to a coolant circulation unit through a pipeline, and the coolant circulation unit injects coolant into the serpentine cooling channel of the diverter arm through the pipeline.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] To address the problem of heat accumulation in the feeder arm under high-intensity working conditions, an active cooling function has been designed. A serpentine cooling channel is designed inside the feeder arm, running through the main heat-exposed areas. Based on temperature sensor data, an algorithm dynamically adjusts the coolant flow and circulation speed to effectively control the feeder arm temperature, avoid thermal deformation-induced reduction in feeder efficiency and damage to the steel plate, and extend the service life of the rubber protective layer.

[0022] Sensors are installed to analyze wear data, calculate the amount of wear and the wear rate, and automatically adjust the tilt angle of the feeding arm based on the wear data. An alarm maintenance function is also set to reduce the workload of manual inspections and adjustments. The system automatically compensates for the angle deviation caused by wear to ensure a stable feeding effect. When the wear exceeds the standard, an alarm is issued in time to avoid production failures and product quality problems caused by equipment wear, thereby improving the intelligence and reliability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] To facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0024] Figure 1 This is a composition diagram of an improved and optimized system for feeding and shifting materials of a straightening machine according to the present invention. DETAILED DESCRIPTION

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0026] See also Figure 1 As shown, a straightening machine feeding and diverting improvement and optimization system includes:

[0027] The feed arm is used to transfer the steel plate from its initial position to the working area of ​​the straightener to complete the loading task. A rubber protective layer is added to the contact surface of the feed arm to further reduce the risk of potential damage to the steel plate surface during the feeding process without affecting the feeding effect. In this way, the feed arm can better protect the material surface while completing the feeding work, thereby improving product quality.

[0028] At the same time, a serpentine cooling channel is designed inside the diverter arm to circulate the coolant, thereby absorbing the heat generated when the diverter arm is working;

[0029] The coolant circulation unit is used to input coolant into the serpentine cooling channel of the diverter arm through the connecting pipe;

[0030] The coolant circulation unit consists of a coolant storage tank, a circulation pump, a temperature sensor, an electric regulating valve and a cooling control unit;

[0031] The coolant is an ethylene glycol aqueous solution, which is used to transfer the heat of the diverter arm. The circulating pump is used to drive the coolant to circulate in the cooling channel. Temperature sensors are installed at the contact point between the diverter arm and the material, the bearing connection point, and the motor drive end of the diverter arm. These parts are prone to heat changes due to friction and load during operation. The sensors can monitor the temperature in real time and transmit the data to the cooling control unit, providing an accurate basis for cooling control. The electric control valve adjusts the flow of the coolant according to the signal from the cooling control unit.

[0032] The adjustment method is based on a pre-written control program, which sets the coolant flow and circulation speed parameters corresponding to different temperature ranges. When the temperature is in the normal range, that is, below 40°C, the electric control valve is controlled to maintain a small opening, even if the coolant flows at a low flow rate of 10L / min and a circulation speed of 0.5m / s to maintain basic heat dissipation. When the temperature approaches the preset threshold of 40°C-50°C, the cooling control unit sends a control instruction to gradually increase the opening of the electric control valve, increase the coolant flow to 15-20L / min, and increase the circulation speed to 0.8-1m / s to enhance heat dissipation. Once the temperature of the dipping arm exceeds the preset threshold of 50°C, the PID control algorithm is immediately used to dynamically adjust the electric control valve and the circulation pump speed according to the deviation between the real-time temperature and the target temperature to ensure that the temperature of the dipping arm drops rapidly and stabilizes within the ideal range of 30°C-40°C.

[0033] The sensor unit is used to collect the contact pressure data of the steel plate surface and the wear depth data of the feed arm;

[0034] The sensor unit is composed of a laser displacement sensor and a pressure sensor, and the distribution of the laser displacement sensor and the pressure sensor is as follows:

[0035] On the working surface where the feeder arm directly contacts the steel plate, three laser displacement sensors are installed at equal intervals of 20 cm along the horizontal direction of the working surface to monitor the wear depth. A pressure sensor is embedded in the center of the working surface to collect contact pressure data with the steel plate surface. Two laser displacement sensors are placed on the outside of the rotation axis at each joint of the feeder arm to monitor the wear caused by friction at the joint in real time.

[0036] The data integration and analysis unit is used to collect monitoring data from the laser displacement sensor and the pressure sensor, analyze and process the data, calculate the wear amount and wear rate of the material diverter arm, and analyze the pressure data to trigger the pressure regulation program according to the analysis results;

[0037] An actuator is used to control the angle device on the material diverter arm to adjust the angle of the material diverter arm according to the analysis result of the data integration and analysis unit;

[0038] Regarding the calculation of wear: a three-dimensional model of the tapping arm in its initial state is established as a benchmark. The point cloud data collected in real time by the laser displacement sensor is compared with the benchmark model. The least squares method is used to fit the surface and the average vertical distance difference between the current contour and the initial contour is calculated. This difference is the real-time wear of the tapping arm.

[0039] Calculation of wear rate: Record the wear data for each fixed time interval (e.g., every hour). Divide the difference between the wear values ​​of two adjacent cycles by the time interval to obtain the wear rate for that period in millimeters per hour. Perform a sliding average on the wear rate data over multiple cycles to reduce errors caused by data fluctuations and obtain a wear rate trend.

[0040] Based on the calculation results, the following adjustment strategy is implemented: the tilt angle of the feeder arm is automatically adjusted according to the wear monitoring data in conjunction with the adjustable angle device of the feeder arm. When the calculated wear exceeds a preset threshold, such as 0.5 mm, or the wear rate exceeds a set rate threshold, such as 0.1 mm / hour, for three consecutive cycles, the situation is defined as severe wear, and the automatic angle adjustment device is activated. Based on the pre-established mathematical model of wear and angle compensation, the wear is calculated and compensated in real time to ensure that the feeder arm and the steel plate surface always maintain the optimal contact angle, thereby ensuring the feeder effect and product quality. At the same time, the system generates an early warning message to prompt maintenance personnel to inspect and replace the feeder arm if it is severely worn.

[0041] For pressure data analysis, pressure fluctuations will be monitored in real time. When the pressure value exceeds the normal working pressure range, that is, higher than 90% or lower than 10% of the rated pressure value, the pressure adjustment program will be automatically triggered. Through the fuzzy control algorithm, combined with the current steel plate thickness and material hardness parameters, the fine-tuning amount of the feed arm angle is calculated; at the same time, when the wear exceeds the set value, the required compensation angle is calculated through the PID adjustment model.

[0042] Example 1:

[0043] The angle compensation adjustment of the feeder arm based on the amount of wear. Taking the hot rolling production line of a steel plant as an example, the laser ranging wear monitoring device on the system collects data on the key contact points of the feeder arm every 15 minutes. When a monitoring finds that the tungsten-cobalt alloy wear-resistant layer at the front end of the No. 1 feeder arm has accumulated wear of 0.6 mm within 8 hours (exceeding the preset threshold of 0.5 mm), and its wear rate has been maintained at 0.12 mm / hour (exceeding the set rate threshold of 0.1 mm / hour) for nearly 3 monitoring cycles (45 minutes), the automatic adjustment mechanism is immediately activated, and the system calls the wear amount-angle compensation mathematical model fitted by 300 sets of experimental data. ,in, Indicates the angle compensation value required, in degrees or radians. This value is used to correct the angle deviation caused by component wear. Represents the cumulative wear of the component, usually in millimeters, reflecting the total wear of the component from the initial state to the current moment. For the wear rate, through this model, the system can accurately calculate the required angle compensation value according to the real-time monitored wear amount and its changing trend, so as to maintain the operating accuracy of the straightening machine feeding and dispensing system. After calculation, the inclination angle of the No. 1 dispensing arm needs to be compensated by +2.1°, and the angle is dynamically adjusted from the current 14.2° to 16.3°, so that the contact angle is restored to the optimal range of 15°±1°. At the same time, an early warning message is pushed to the central control room: the wear of the No. 1 dispensing arm exceeds the limit, the current wear amount is 0.6mm, and it is recommended to complete the replacement within 48 hours, and generate a maintenance work order including the wear curve and compensation parameters. After on-site verification, the dispensing success rate is increased from 89% to 98.5% after adjustment, which effectively avoids the problem of scratches on the steel plate surface caused by angle deviation.

[0044] Example 2:

[0045] Angle adjustment based on pressure data. In a certain straightening machine application scenario, when producing a batch of high-strength steel plates with a thickness of 5mm and a material of Q345B, the pressure sensor detected that the contact pressure suddenly climbed to 110% of the rated pressure. The system immediately started the pressure adjustment program and fine-tuned the angle of the feed arm by 2.3° according to the steel plate parameters and fuzzy control algorithm to restore the pressure to the normal range.

[0046] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to the specific embodiments described. Obviously, many modifications and variations are possible based on the content of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A straightening machine feeding and selecting improvement and optimization system, characterized in that: include: The diverter arm is used to transfer the steel plate from the initial position to the working area of ​​the straightening machine to complete the loading task. The diverter arm is designed with a serpentine cooling channel inside. The serpentine cooling channel is used for the circulation of coolant to absorb the heat generated by the diverter arm when working; The coolant circulation unit is used to input coolant into the serpentine cooling channel of the diverter arm through the connecting pipe; The sensor unit is used to collect the contact pressure data of the steel plate surface and the wear depth data of the feed arm; The data integration and analysis unit is used to collect monitoring data from the laser displacement sensor and the pressure sensor, analyze and process the data, calculate the wear amount and wear rate of the material diverter arm, and analyze the pressure data to trigger the angle adjustment program according to the analysis results; The actuator is used to control the angle device on the material diverter arm to adjust the angle of the material diverter arm according to the analysis results of the data integration and analysis unit.

2. A straightening machine feeding and selecting improvement and optimization system according to claim 1, characterized in that: The coolant circulation unit consists of a coolant storage tank, a circulation pump, a temperature sensor, an electric control valve and a cooling control unit. The coolant storage tank is used to store coolant, the circulation pump is used to drive the coolant to circulate in the cooling channel, and the temperature sensor is installed at the contact point between the material feeding arm and the material, the bearing connection point and the motor drive end position of the material feeding arm, and is used to monitor the temperature in real time and transmit the data to the cooling control unit. The cooling control unit is used to generate a control signal according to the temperature parameter, and the electric control valve adjusts the flow of coolant according to the control signal generated by the cooling control unit.

3. The straightening machine feeding and selecting improvement and optimization system according to claim 1 is characterized in that: The sensor unit consists of a laser displacement sensor and a pressure sensor. The laser displacement sensor is arranged on the working surface where the material feeding arm is in direct contact with the steel plate to monitor the wear depth. The pressure sensor is embedded and installed at the center of the working surface to collect contact pressure data with the steel plate surface.

4. The straightening machine feeding and selecting improvement and optimization system according to claim 1 is characterized in that: The wear amount is calculated as follows: by establishing a three-dimensional model of the material tapping arm in the initial state as a benchmark, the point cloud data collected in real time by the laser displacement sensor is compared with the benchmark model, and the least squares method is used to fit the surface to calculate the average distance difference between the current contour and the initial contour in the vertical direction. This difference is the real-time wear amount of the material tapping arm.

5. The straightening machine feeding and selecting improvement and optimization system according to claim 1 is characterized in that: The wear rate is calculated as follows: at fixed time intervals, the wear data within each cycle is recorded, the difference in wear between two adjacent cycles is divided by the time interval to obtain the wear rate within the time period, and the wear rate data of multiple cycles is subjected to sliding average processing to reduce the error caused by data fluctuations and obtain the wear rate trend.

6. A straightening machine feeding and selecting improvement and optimization system according to claim 1, characterized in that: A rubber protective layer is provided on the contact surface of the material-diverting arm, and the rubber protective layer is used to reduce damage to the surface of the steel plate during the material-diverting process.

7. The straightening machine feeding and selecting improvement and optimization system according to claim 2 is characterized in that: The generation process of the adjustment signal is as follows: setting the coolant flow and circulation speed parameters corresponding to different temperature intervals; when the temperature is in the normal range, controlling the electric control valve to make the coolant flow at a predetermined flow and circulation speed to maintain basic heat dissipation; when the temperature approaches a preset threshold, increasing the coolant flow and the circulation speed to enhance heat dissipation; once the temperature of the material feeding arm exceeds the preset threshold, the PID control algorithm is immediately used to dynamically adjust the electric control valve and the circulation pump speed according to the deviation between the real-time temperature and the target temperature to ensure that the temperature of the material feeding arm drops rapidly and stabilizes within the set range.

8. The straightening machine feeding and selecting improvement and optimization system according to claim 1 is characterized in that: The angle adjustment program specifically includes: automatically adjusting the tilt angle of the feeder arm based on wear monitoring data; when the calculated wear exceeds a preset threshold, or the wear rate exceeds the set rate threshold for three consecutive cycles, the situation is defined as severe wear, and the automatic angle adjustment device is activated. The wear is calculated and compensated in real time based on a pre-established mathematical model of wear and angle compensation. At the same time, the system generates an early warning message to prompt maintenance personnel to inspect and replace the severely worn feeder arm; For pressure data analysis, pressure fluctuations will be monitored in real time. When the pressure value exceeds the set range, the pressure adjustment program will be automatically triggered. Through the fuzzy control algorithm, combined with the current steel plate thickness and material hardness parameters, the fine-tuning amount of the feed arm angle will be calculated.

9. A straightening machine feeding and selecting improvement and optimization system according to claim 2, characterized in that: The cooling liquid is ethylene glycol water solution, which is used to transfer the heat of the feeding arm.

10. The straightening machine feeding and selecting improvement and optimization system according to claim 1, characterized in that: The diverter arm is connected to a coolant circulation unit through a pipeline, and the coolant circulation unit injects coolant into the serpentine cooling channel of the diverter arm through the pipeline.

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