A die loading height monitoring and adjusting system and method for a double knuckle-joint large-tonnage press

Abstract

The present application relates to the technical field of forging equipment, especially to a die loading height monitoring and adjusting system and method for a double-toggle large-tonnage press, which installs various sensors at key positions of the press to collect real-time working data; through signal processing and analog-to-digital conversion, the analog signals are converted into digital signals, optimized, and height-related signals and compensation-related signals are extracted; then, the die loading estimated height is calculated, and the estimated height is adjusted through a compensation algorithm to obtain the current die loading height; according to the comparison between the current height and the preset height, it is determined whether to adjust, and the die height is accurately adjusted through a hydraulic system; the whole adjusting process adopts closed-loop control to ensure the accuracy and repeatability of the adjustment; the present application effectively improves the precision and efficiency of die loading operation, reduces the operation difficulty, and enhances the reliability and productivity of the press.

Description

Technical Field

[0001] This invention relates to the field of forging equipment technology, and in particular to a system and method for monitoring and adjusting the die mounting height of a double-elbow-bar high-tonnage press. Background Technology

[0002] In traditional double-elbow-lever high-tonnage presses, the adjustment of the die mounting height typically relies on the operator's experience and manual measurement. This method is not only inefficient but also has limited accuracy, easily leading to improper die installation and affecting product quality and production efficiency. With the development of manufacturing processes, the requirements for die mounting accuracy in presses are becoming increasingly stringent, and traditional manual adjustment methods can no longer meet the needs of modern production. Therefore, developing a system capable of automatically monitoring and adjusting the die mounting height has become particularly important.

[0003] For example, Chinese patent CN104439012A discloses a die height adjustment device for an MP hot forging press, including an eccentric pressure shaft, a slider, a clamping cover, a clamping head, and an eccentric pressure shaft angle adjustment device. The eccentric pressure shaft angle adjustment device includes a cylinder, a cylinder cover, a piston, a rack, and a piston drive mechanism. The cylinder is mounted on the end face of the slider, and the cylinder cover is connected to the cylinder to form a sealed cavity. The piston is located inside the cylinder, dividing the sealed cavity into a left cavity and a right cavity. The piston drive mechanism drives the piston to move within the sealed cavity. The rack is installed inside the slider and is connected to the piston via a piston rod. A first sliding bearing and a support are sequentially arranged between the right end of the rack and the slider, and a second sliding bearing is arranged between the left end of the rack and the slider. Teeth are provided on the outer surface of the eccentric pressure shaft, and the eccentric pressure shaft and the rack are connected by a gear and rack transmission. This device has advantages such as simple structure, low manufacturing and production costs, long service life, and convenient maintenance.

[0004] The above patents have the problems mentioned in the background art: the height estimation and compensation methods are not accurate enough and cannot fully reflect the actual height changes, resulting in inaccurate adjustment. In order to solve the above problems, this application designs a mold mounting height monitoring and adjustment system and method for a double elbow lever large tonnage press. Summary of the Invention

[0005] The technical problem this invention aims to solve is to address the shortcomings of existing technologies by providing a mold mounting height monitoring and adjustment system and method for a double-elbow-lever high-tonnage press. Multiple sensors are installed at key parts of the press to collect real-time operational data. Through signal processing and analog-to-digital conversion, analog signals are converted into digital signals, optimized, and height-related and compensation-related signals are extracted. The estimated mold mounting height is then calculated and adjusted using a compensation algorithm to obtain the current mold mounting height. Based on a comparison between the current mold mounting height and the preset height, a decision is made whether to adjust the height, which is then precisely adjusted via a hydraulic system. The entire adjustment process employs closed-loop control to ensure accuracy and repeatability.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press, the method comprising:

[0008] Sensor assemblies are installed at the elbow joint of the press, the mold contact surface, and the mold frame to collect real-time sensor data;

[0009] The real-time sensor data is processed to generate the current mold mounting height. The current mold mounting height is compared with the preset height to determine whether the height needs to be adjusted.

[0010] If height adjustment is required, the mold height can be adjusted using the height adjustment device.

[0011] The acquisition of real-time sensor data includes:

[0012] Data acquisition: Analog signal data is acquired through sensors at various measurement locations. The analog signal data includes displacement, pressure, temperature, angle, and vibration information.

[0013] Signal conditioning: Conditioning the analog signal data;

[0014] Analog-to-digital conversion: Converting conditioned analog signal data into digital signals using an analog-to-digital converter.

[0015] The processing of the real-time sensor data includes:

[0016] Real-time sensor data is preprocessed to extract highly correlated signals and compensate for the correlation signals;

[0017] The estimated mold-installation height is calculated based on the height correlation signal, and the estimated mold-installation height is compensated by the compensation correlation signal to calculate the current mold-installation height.

[0018] The preprocessing of real-time sensor data includes:

[0019] Statistical analysis is performed on the digital signal, and an optimized signal value is calculated using an optimization function. This optimized signal value is then normalized. The formula for calculating the optimized signal value is as follows:

[0020]

[0021] Where, N s S represents a digital signal. o Let X represent the optimized signal value, σ represent the variance of the digital signal, θ represent the adjustment parameters of the optimization function, γ1 and γ2 represent the weighting coefficients of the digital signal, ε represent the noise characteristics of the digital signal, α represent the scaling factor of the optimization function, and X represent the signal optimization value. e X represents the deviation value of abnormal digital signal data. o This represents the observed values ​​of digital signal anomaly data;

[0022] The initial parameters of the Kalman filter are initialized using prior knowledge. The normalized optimized signal value is input into the Kalman filter, which then fine-tunes the initial parameters, calculates the tuning parameters, and outputs the optimal digital signal based on the tuning parameters.

[0023] The optimal digital signals from the displacement sensor, pressure sensor, and angle sensor are labeled as highly correlated signals, while the optimal digital signals from the temperature sensor and vibration sensor are labeled as compensated correlated signals.

[0024] The step of calculating the estimated height of the mold based on the height correlation signal includes:

[0025] The displacement contribution value is calculated based on the optimal digital signal from the displacement sensor. The formula for calculating the displacement contribution value is as follows:

[0026]

[0027] Among them, M c The displacement contribution value is represented by S, which represents the conversion coefficient of the displacement sensor, and d. b K represents the optimal digital signal of the displacement sensor installed at the elbow joint. r The correction factor is represented by j, which represents a single displacement sensor installed on the mold contact surface, and J represents the total number of displacement sensors installed on the mold contact surface. rj ω represents the optimal digital signal of the j-th displacement sensor installed on the mold contact surface. j K represents the displacement weight value of the j-th displacement sensor installed on the mold contact surface. f Denotes the compensation coefficient, d f The optimal digital signal, δ, represents the displacement sensor installed at the mold frame location. b δ f and δr Indicates the weighting coefficient;

[0028] The high coupling value is calculated based on the optimal digital signals from the pressure sensor and the angle sensor.

[0029] Based on the displacement contribution value and the height coupling value, calculate the estimated mold height H. p =M c +H c , where H p H represents the estimated height of the mold assembly. c This indicates a highly coupled value.

[0030] The compensation of the estimated height of the mold assembly using the compensation-related signal includes:

[0031] Calculate the temperature compensation term based on the optimal digital signal from the temperature sensor;

[0032] The optimal digital signal of the vibration sensor is analyzed by Fourier transform to identify abnormal vibration frequencies, and vibration compensation terms are calculated based on the abnormal vibration frequencies.

[0033] Based on the estimated mold assembly height, temperature compensation, and vibration compensation, the current mold assembly height is calculated. The formula for calculating the current mold assembly height is as follows:

[0034]

[0035] Among them, H n T represents the current mold height, λ represents the temperature sensitivity coefficient of the press material, and T represents the temperature of the mold. n The abnormal temperature during the operation of the press is represented by T, the normal operating temperature of the press is represented by η, and the vibration compensation coefficient is represented by η, which is obtained through experimental calibration; z represents a single abnormal vibration frequency during the operation of the press, Z represents the total number of abnormal vibration frequencies during the operation of the press, and V represents the abnormal vibration frequency of the press. z Let represent the z-th abnormal vibration frequency, and V represent the standard vibration frequency of the press.

[0036] The method of adjusting the mold height via a height adjustment device includes:

[0037] Calculate the height deviation value based on the current mold height and the preset height, and determine the adjustment direction based on the positive or negative value of the height deviation value. Calculate the adjustment amplitude through a step-by-step adjustment method.

[0038] The controller sends control commands to the hydraulic cylinder based on the adjustment direction and the adjustment amplitude;

[0039] According to the control command, the speed at which hydraulic oil enters the hydraulic cylinder is changed, and the height of the mold is adjusted by controlling the flow rate and pressure of the hydraulic oil.

[0040] During the adjustment process, the actual position of the mold is monitored in real time, and the height is fed back to the controller. The controller compares the fed-back height with the preset height. If there is still a height difference, the adjustment amplitude is recalculated and the control command is updated.

[0041] When the controller confirms that there is no height difference, it generates a stop command and locks the current mold position through the locking device.

[0042] A mold mounting height monitoring and adjustment system for a double elbow lever high-tonnage press, the system comprising a data acquisition module, a data processing module, a height calculation module, and a height adjustment module;

[0043] The data acquisition module is used to install sensor components on the press and acquire analog signal data from each sensor.

[0044] The data processing module is configured with a data processing strategy, which is used to convert analog signal data into digital signals, preprocess the digital signals, extract highly correlated signals, and compensate for correlated signals.

[0045] The height calculation module is configured with a height calculation strategy. The height calculation strategy calculates the estimated height of the formwork based on the height-related signal, compensates the estimated height of the formwork based on the compensation-related signal, and calculates the current formwork height.

[0046] The height adjustment module adjusts the mold mounting height of the press through a height adjustment device.

[0047] The data processing module includes:

[0048] The signal conversion unit is used to condition analog signal data and convert the conditioned analog signal data into digital signals through an analog-to-digital converter.

[0049] The signal preprocessing unit is used to perform statistical analysis on the digital signal, calculate the optimized signal value through the optimization function, normalize the optimized signal value, output the optimal digital signal through the Kalman filter, mark the optimal digital signal from the displacement sensor, pressure sensor and angle sensor as highly correlated signal, and mark the optimal digital signal from the temperature sensor and vibration sensor as compensated correlation signal.

[0050] The data processing strategy includes signal conversion logic and signal classification logic. The signal conversion logic is used to convert analog signal data into digital signals and is configured within the signal conversion unit. The signal classification logic is used to preprocess the digital signals, extract highly correlated signals and compensate for correlated signals, and is configured within the signal preprocessing unit.

[0051] The height calculation module includes:

[0052] The height estimation unit calculates the estimated height of the mold based on the optimal digital signals from the displacement sensor, pressure sensor, and angle sensor.

[0053] A height compensation unit is used to calculate temperature compensation and vibration compensation, and to calculate the current mold installation height based on the estimated mold installation height, temperature compensation, and vibration compensation.

[0054] The altitude calculation strategy includes altitude estimation logic and actual altitude calculation logic;

[0055] The height prediction calculation logic calculates the displacement contribution value based on the optimal digital signal from the displacement sensor, calculates the height coupling value based on the optimal digital signals from the pressure sensor and the angle sensor, and calculates the estimated height of the mold based on the displacement contribution value and the height coupling value.

[0056] The actual height calculation logic calculates the temperature compensation term based on the optimal digital signal of the temperature sensor, performs frequency analysis on the optimal digital signal of the vibration sensor through Fourier transform to identify abnormal vibration frequencies, calculates the vibration compensation term based on the abnormal vibration frequencies, and calculates the current mold installation height based on the estimated mold installation height, the temperature compensation term, and the vibration compensation term.

[0057] The height prediction calculation logic is configured within the height prediction unit, and the actual height calculation logic is configured within the height compensation unit.

[0058] Compared with the prior art, the beneficial effects of the present invention are:

[0059] 1. This invention uses signal processing technology to condition and optimize the acquired analog signals, including signal optimization using a Kalman filter, and improving the efficiency and accuracy of data processing through the extraction and calculation of highly correlated signals and compensated correlation signals;

[0060] 2. This invention improves the accuracy of mold height detection by estimating and compensating for the mold height, thereby calculating the actual mold height.

[0061] 3. This invention reduces the need for manual intervention during the mold-making process through an automated monitoring and adjustment system, thereby reducing operational difficulty and labor intensity. It can quickly adjust the mold height, reduce mold-making time, and thus improve production and processing efficiency. Attached Figure Description

[0062] Other features, objects, and advantages of the invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0063] Figure 1 This is a flowchart illustrating a method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press according to Embodiment 1 of the present invention.

[0064] Figure 2 This is a flowchart of analog signal data preprocessing in Embodiment 1 of the present invention;

[0065] Figure 3 This is a schematic diagram of the analog-to-digital conversion process in Embodiment 1 of the present invention;

[0066] Figure 4 This is a flowchart of digital signal preprocessing in Embodiment 1 of the present invention;

[0067] Figure 5 This is a schematic diagram illustrating the calculation of the estimated height of the mold in Embodiment 1 of the present invention;

[0068] Figure 6 This is a schematic diagram illustrating the calculation of the current mold mounting height in Embodiment 1 of the present invention;

[0069] Figure 7 This is a module diagram of a mold mounting height monitoring and adjustment system for a double elbow lever large-tonnage press according to Embodiment 2 of the present invention. Detailed Implementation

[0070] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0071] Example 1

[0072] Please see Figure 1 The present invention provides an embodiment of a method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press, the specific steps of which are as follows:

[0073] S1: A sensor assembly is arranged at the measuring part of the double elbow lever high-tonnage press to collect the press's working data.

[0074] In this step, the measurement location refers to the key structural position of the press. These positions have an important impact on the performance of the press, the stability of the mold height, and the overall machining accuracy. Specifically, they include the elbow connection of the press, the mold contact surface, and the mold frame position. The sensor assembly includes a displacement sensor, a pressure sensor, an angle sensor, a temperature sensor, and a vibration sensor. The press working data includes displacement, pressure, temperature, angle, and vibration information.

[0075] S2: Preprocess the press's operating data and convert it into digital signals;

[0076] S3: Normalize the digital signal, eliminate redundant data through a Kalman filter, and divide the digital signal into highly correlated signals and compensated correlated signals;

[0077] In this step, the digital signals acquired and converted from the sensor are further processed to ensure the accuracy and relevance of the data. This mainly includes three sub-steps: normalization of the digital signals, application of Kalman filters, and classification and processing of the signals.

[0078] S4: Calculate the estimated mold assembly height based on the height correlation signal, compensate the estimated mold assembly height using the compensation correlation signal, and calculate the current mold assembly height;

[0079] S5: Compare the current mold height with the preset height to determine whether the height needs to be adjusted;

[0080] S6: If height adjustment is required, the mold height can be adjusted using the height adjustment device;

[0081] The elbow joint is the core part of the press torque transmission, bearing huge pressure and stress changes, and is an important factor affecting the accuracy of the press. The movement and force of the elbow directly affect the height change of the mold. The mold contact surface is the part where the press contacts the workpiece and is the direct point of force application. The height change here directly reflects the accuracy of the mold mounting height. The mold frame is the structural component that fixes the mold, and its stability directly affects the accuracy of the mold mounting height. The position, angle and temperature changes of the mold frame will all affect the mold mounting height.

[0082] Please see Figure 2 The flowchart of analog signal data preprocessing in this embodiment of the invention is as follows: Step S2 is specifically described below:

[0083] S2.1: Conditioning the analog signal data, the conditioning including signal amplification and time synchronization;

[0084] The raw signals output by sensors may be very weak. Signal amplifiers amplify these weak signals to a range suitable for subsequent processing, ensuring signal clarity and detectability. In multi-sensor systems, the time of data from each sensor is synchronized to guarantee the timeliness and consistency of data fusion. By using a synchronized clock mechanism, data from different sensors can be acquired and processed under the same time reference.

[0085] S2.2: Convert the conditioned analog signal data into a digital signal using an analog-to-digital converter;

[0086] Since the signals output by sensors are usually analog signals, while computers can process digital signals, analog signals need to be converted into digital signals by analog-to-digital converters. The key factors in the analog-to-digital conversion process include sampling frequency, quantization resolution, and dynamic range of the signal. These factors directly affect the accuracy of data processing and the accuracy of the final mold height calculation.

[0087] Please see Figure 3 The schematic diagram of the analog-to-digital conversion process in this embodiment of the invention shows the specific steps in S2.2 as follows:

[0088] S2.2.1: Discretize the continuous analog signal in time, sample the analog signal data according to the sampling period to obtain the discrete signal. The sampling period is selected according to the operating speed and dynamic response requirements of the press, ensuring that the sampling frequency is higher than the acquisition frequency to prevent aliasing.

[0089] S2.2.2: Map the discrete signal to discrete amplitude levels, where the discrete amplitude levels are determined by the number of bits in the analog-to-digital converter (ADC). An ADC with a resolution of N can divide the signal into 22... N Each discrete amplitude level;

[0090] S2.2.3: The mapped discrete amplitude level signal is shifted to change the position of discontinuities. The signal is then smoothed using wavelet transform. The smoothed signal is then reverse-shifted, and the digital signal is calculated. The formula for calculating the digital signal is as follows:

[0091]

[0092] Where, N s Let S represent a digital signal, where n represents the number of discontinuities in the mapped discrete amplitude level signal, h represents the h-th discontinuity in the mapped discrete amplitude level signal, and S... h This represents shifting the h-th discontinuity in the mapped discrete amplitude level signal, S. -h This represents the inverse shift of the h-th discontinuity in the mapped discrete amplitude level signal, where T represents wavelet transform, ε represents the analog-to-digital conversion coefficient, and V... ref This indicates the operating voltage of the analog-to-digital converter, V. i Let represent the analog signal voltage at the i-th sampling time, → represent the mapping function, and μ represent the quantization standard error;

[0093] Please see Figure 4 The digital signal preprocessing flowchart of this embodiment of the invention, the specific steps of S3 are as follows:

[0094] S3.1: Perform statistical analysis on the digital signal, calculate the optimized signal value through an optimization function, and normalize the optimized signal value;

[0095] By statistically analyzing and optimizing digital signals, we can accurately analyze the characteristics of sensor data and improve the reliability and accuracy of the data through optimization algorithms. This step of the technical implementation is divided into the following parts: signal statistical analysis, calculation of optimization functions, and signal normalization processing.

[0096] Statistical analysis of digital signals involves extracting basic statistical features from the acquired sensor data, including calculating the variance, mean, and standard deviation of each type of data. This provides a preliminary understanding of the overall trend and fluctuation of various types of sensor data. These statistics provide the basic data for subsequent signal optimization and normalization, making the optimization and processing more accurate.

[0097] Based on statistical analysis, the signal is further processed using an optimization function to calculate the optimized value. The purpose of this step is to eliminate noise and outliers through optimization algorithms, extracting the optimized value that represents the essence of the signal. The formula for calculating the optimized signal value is as follows:

[0098]

[0099] Among them, S o Let X represent the optimized signal value, σ represent the variance of the digital signal, θ represent the adjustment parameters of the optimization function, γ1 and γ2 represent the weighting coefficients of the digital signal, which are adjusted to optimize the contribution of different signal components so that the final optimized signal better represents the characteristics of the signal, ε represent the noise characteristics of the digital signal, α represent the scaling factor of the optimization function, and X represent the signal optimization value. e X represents the deviation value of abnormal digital signal data. o This represents the observed values ​​of digital signal anomaly data;

[0100] The optimized signal values ​​need to be further normalized to facilitate integrated processing and comparison with other signals. Normalization can eliminate differences in signal magnitudes and bring them within the same scale range. The normalized signal provides a unified input basis for subsequent height adjustment algorithms, improving the accuracy of data fusion and decision-making.

[0101] S3.2: Initialize the initial parameters of the Kalman filter using prior knowledge. The initial parameters include the state estimate, error covariance, and noise covariance matrix. Input the normalized optimized signal value into the Kalman filter. The Kalman filter fine-tunes the initial parameters, calculates the fine-tuning parameters, and outputs the optimal digital signal based on the fine-tuning parameters.

[0102] The Kalman filter is a recursive optimal estimation algorithm widely used in signal processing, control systems, and data fusion. Based on the current estimated value of sensor data and prior information (such as the system's state model), the Kalman filter predicts and corrects the signal at each moment, ultimately obtaining the optimal estimation result. Its core idea is to generate the most probable current state estimate by combining Bayesian estimation with prior estimates and actual sensor measurement data. In this step, the Kalman filter is used to filter the normalized sensor data, eliminating redundant and noisy data and improving signal accuracy.

[0103] S3.3: The optimal digital signals from the displacement sensor, pressure sensor, and angle sensor are marked as highly correlated signals, and the optimal digital signals from the temperature sensor and vibration sensor are marked as compensated correlated signals;

[0104] After processing with a Kalman filter, the digital signals are divided into two categories: highly correlated signals and compensated correlated signals. This classification step is to clarify the role of different signals in mold height monitoring and adjustment, and to perform subsequent processing accordingly.

[0105] Height-related signals refer to data signals that directly affect the mold mounting height, mainly including processed signals from displacement sensors, pressure sensors, and angle sensors. These signals reflect the actual position of the mold, pressure distribution, and frame tilt, and are directly used to calculate the current mold mounting height and adjust it in real time.

[0106] The displacement signal reflects the vertical distance between the mold contact surface and the reference surface, and is the most direct indicator of the mold mounting height. The pressure signal can infer the deformation of the mold during the pressure application process, thereby adjusting the mold mounting height to ensure the accuracy of the height. The angle signal is used to detect the degree of tilt of the mold frame and calculate the mold mounting height based on the height difference caused by the tilt of the frame.

[0107] Compensation-related signals include processed signals from temperature and vibration sensors. Although these signals do not directly reflect height, they affect the accuracy of mold height estimation and are used to correct height-related signals through compensation calculations.

[0108] Temperature changes cause materials to expand or contract, thus affecting the mold height. Temperature compensation can correct for temperature-related errors in height calculations, maintaining measurement accuracy. Vibration can cause transient instability in measurements, leading to fluctuations in the measurement signal. Vibration signal analysis and compensation can filter out measurement errors caused by vibration, ensuring smooth height adjustment.

[0109] The height-related signal is used for real-time height adjustment and directly affects the estimated value of the mold assembly height; the compensation-related signal is used to correct the estimation error of the mold assembly height and the influence of the environment. By processing these two types of signals independently and superimposing the compensation results into the height adjustment algorithm, comprehensive optimization can be achieved.

[0110] Please see Figure 5 A schematic diagram illustrating the calculation of the estimated height for mold assembly according to an embodiment of the present invention. The step of calculating the estimated height for mold assembly based on the height-related signal includes:

[0111] The basic displacement value is calculated based on the optimal digital signal from a displacement sensor installed at the elbow joint. This displacement sensor directly measures the displacement change of the elbow under pressure, reflecting the basic positional change of the mold during loading, which helps to understand the basic changes in the mold's position during stress. Direct measurement at the elbow joint allows for capturing the displacement response of the press during loading, ensuring the accuracy of the calculation.

[0112] The displacement correction value is calculated based on the optimal digital signal from the displacement sensor installed on the mold contact surface. This calculation compensates for displacement deviations caused by uneven stress on the mold or uneven mold surface. To capture the displacement at different points on the mold surface, multiple sensors can be installed, and weighted averaging can be used to identify local height differences on the mold surface, compensating for errors caused by uneven surface or uneven loading. This correction ensures greater consistency in height between contact points during mold assembly, improving overall machining accuracy.

[0113] The displacement compensation value is calculated based on the optimal digital signal from the displacement sensor installed at the mold frame location. This value compensates for displacement errors caused by changes in the overall position or tilt of the mold frame. It effectively corrects height errors caused by frame deformation, tilting, or positional movement, ensuring that the final height estimate reflects the actual working state of the mold. Precise measurement of frame position changes allows for better control of the mold height stability, which is particularly important in applications involving large-tonnage presses.

[0114] Based on the aforementioned basic displacement value, displacement correction value, and displacement compensation value, a weighted average displacement contribution value is calculated. This effectively integrates displacement information from the elbow, mold contact surface, and mold frame position, generating a contribution value that reflects the overall mold height change. It considers the different impacts of displacement at different locations on the final height, ensuring precise control of the mold installation height. The formula for calculating the displacement contribution value is:

[0115]

[0116] Among them, M cThe displacement contribution value is represented by S, which represents the conversion coefficient of the displacement sensor and determines the conversion relationship between the displacement sensor signal and the actual displacement value. b K represents the optimal digital signal of the displacement sensor installed at the elbow joint. r The correction factor is represented by j, which represents a single displacement sensor installed on the mold contact surface, and J represents the total number of displacement sensors installed on the mold contact surface. rj ω represents the optimal digital signal of the j-th displacement sensor installed on the mold contact surface. j K represents the displacement weight value of the j-th displacement sensor installed on the mold contact surface, reflecting the importance of different measurement points. f The compensation coefficient, d, is typically calibrated based on the frame's stiffness and geometric properties. f The optimal digital signal, δ, represents the displacement sensor installed at the mold frame location. b δ f and δ r This represents the weighting coefficient, which is adjusted based on experimental data and application experience to reflect the relative importance of different displacement components;

[0117] In the press system, pressure sensors and angle sensors are installed on the mold contact surface and mold frame, respectively, to monitor changes in mold force and tilt angle. The output signals of these two sensors directly affect the coupling calculation of the mold height. Under pressure, the mold will compress or displace; this deformation is proportional to the pressure value. The tilt of the mold frame changes the mold contact state, thus affecting the effect of pressure on height. Therefore, the signal from the angle sensor is introduced to correct the height calculation. Based on the optimal digital signals from the pressure and angle sensors, the height coupling value is calculated. The formula for calculating the height coupling value is as follows:

[0118]

[0119] Among them, H c K represents the high coupling value. p This represents the coefficient of influence of pressure on height, specifically the change in mold height for every one Pa increase in the pressure sensor reading, P. p This represents the optimal digital signal of the pressure sensor installed on the mold contact surface. τ represents the tilt angle, and τ represents the nonlinear coefficient.

[0120] Based on the displacement contribution value and the height coupling value, calculate the estimated mold height H. p =M c +H c , where H p H represents the estimated height of the mold assembly. c Indicates a highly coupled value;

[0121] Please see Figure 6 This invention provides a schematic diagram of the current mold assembly height calculation. The step of compensating the estimated mold assembly height using the compensation-related signal includes:

[0122] The operating temperature of the press is obtained by a temperature sensor installed at the elbow joint. This operating temperature is compared with the normal operating temperature of the press to determine if temperature compensation is needed. If compensation is required, a temperature compensation term is calculated using an exponential decay model to ensure that the mold height maintains high accuracy under different temperature conditions. Especially in high or low temperature environments, temperature compensation can prevent height errors caused by thermal expansion or contraction.

[0123] The vibration signal of the press is obtained by a vibration sensor installed on the contact surface of the mold. The optimal digital signal of the vibration sensor is analyzed by Fourier transform to identify abnormal vibration frequencies. A vibration compensation term is calculated based on the abnormal vibration frequencies. The vibration compensation term is used to reduce the transient impact of mechanical vibration on the mold height. Especially when abnormal vibration is encountered during processing, the compensation term can effectively suppress the height fluctuation caused by vibration and ensure the stability of the mold height.

[0124] Based on the estimated mold installation height, temperature compensation, and vibration compensation, the current mold installation height is calculated. Height compensation is performed using the optimal digital signals from temperature and vibration sensors. This effectively corrects for the impact of environmental changes and abnormal vibrations on the mold installation height, adapting to complex working conditions and ensuring precise control of the mold installation height. The formula for calculating the current mold installation height is as follows:

[0125]

[0126] Among them, H n T represents the current mold mounting height, λ represents the temperature sensitivity coefficient of the press material, used to reflect the effect of temperature changes on the height. n The abnormal temperature during the operation of the press is represented by T, the normal operating temperature of the press is represented by η, and the vibration compensation coefficient is represented by η, which is obtained through experimental calibration; z represents a single abnormal vibration frequency during the operation of the press, Z represents the total number of abnormal vibration frequencies during the operation of the press, and V represents the abnormal vibration frequency of the press. z denoted by z, where z represents the z-th abnormal vibration frequency, and V represents the standard vibration frequency of the press.

[0127] The height adjustment device includes:

[0128] Hydraulic cylinder: As an actuator, it directly controls the up and down movement of the mold, changing the mold mounting height. The hydraulic cylinder precisely controls the height by adjusting the flow and pressure of the hydraulic oil.

[0129] Transmission mechanism: including lead screw, gear transmission system, etc., converts the action of hydraulic cylinder into linear displacement of mold. These mechanical components ensure the smoothness and accuracy of transmission.

[0130] Controller: The controller includes a PLC, which receives data from sensors and issues commands to drive the hydraulic cylinder according to a set control algorithm.

[0131] Position feedback system: including a linear encoder, used to monitor the position of the mold in real time to ensure the accuracy and stability of adjustment;

[0132] Locking device: includes a hydraulic lock for locking the mold position;

[0133] The method of adjusting the mold height via a height adjustment device includes:

[0134] Calculate the height deviation value based on the current mold height and the preset height, and determine the adjustment direction based on the positive or negative value of the height deviation value. Calculate the adjustment amplitude through a step-by-step adjustment method.

[0135] The controller sends control commands to the hydraulic cylinder based on the adjustment direction and the adjustment amplitude;

[0136] According to the control command, the speed at which hydraulic oil enters the hydraulic cylinder is changed, and the height of the mold is adjusted by controlling the flow rate and pressure of the hydraulic oil.

[0137] During the adjustment process, the actual position of the mold is monitored in real time, and the height is fed back to the controller. The controller compares the fed-back height with the preset height. If there is still a height difference, the adjustment amplitude is recalculated and the control command is updated.

[0138] When the controller confirms that there is no height difference, it generates a stop command and locks the current mold position through the locking device;

[0139] Through real-time feedback and closed-loop control, errors in the adjustment process can be continuously corrected to ensure that the final height reaches the preset target. It can automatically adjust control parameters (such as adjustment speed, step size, and threshold) according to different working conditions (such as molds made of different materials or different processing techniques), thereby improving the adaptability and intelligence level of mold height adjustment.

[0140] Example 2

[0141] Please see Figure 7 The present invention provides an embodiment of a mold mounting height monitoring and adjustment system for a double elbow lever high-tonnage press, the system comprising a data acquisition module, a data processing module, a height calculation module and a height adjustment module;

[0142] The data acquisition module is used to install sensor components on the press and acquire analog signal data from each sensor.

[0143] The data processing module is configured with a data processing strategy, which is used to convert analog signal data into digital signals, preprocess the digital signals, extract highly correlated signals, and compensate for correlated signals.

[0144] The height calculation module is configured with a height calculation strategy. The height calculation strategy calculates the estimated height of the formwork based on the height-related signal, compensates the estimated height of the formwork based on the compensation-related signal, and calculates the current formwork height.

[0145] The height adjustment module adjusts the mold mounting height of the press through a height adjustment device.

[0146] The data processing module includes:

[0147] The signal conversion unit is used to condition analog signal data and convert the conditioned analog signal data into digital signals through an analog-to-digital converter.

[0148] The signal preprocessing unit is used to perform statistical analysis on the digital signal, calculate the optimized signal value through the optimization function, normalize the optimized signal value, output the optimal digital signal through the Kalman filter, mark the optimal digital signal from the displacement sensor, pressure sensor and angle sensor as highly correlated signal, and mark the optimal digital signal from the temperature sensor and vibration sensor as compensated correlation signal.

[0149] The data processing strategy includes signal conversion logic and signal classification logic. The signal conversion logic is used to convert analog signal data into digital signals and is configured within the signal conversion unit. The signal classification logic is used to preprocess the digital signals, extract highly correlated signals and compensate for correlated signals, and is configured within the signal preprocessing unit.

[0150] The height calculation module includes:

[0151] The height estimation unit calculates the estimated height of the mold based on the optimal digital signals from the displacement sensor, pressure sensor, and angle sensor.

[0152] A height compensation unit is used to calculate temperature compensation and vibration compensation, and to calculate the current mold installation height based on the estimated mold installation height, temperature compensation, and vibration compensation.

[0153] The altitude calculation strategy includes altitude estimation logic and actual altitude calculation logic;

[0154] The height prediction calculation logic calculates the displacement contribution value based on the optimal digital signal from the displacement sensor, calculates the height coupling value based on the optimal digital signals from the pressure sensor and the angle sensor, and calculates the estimated height of the mold based on the displacement contribution value and the height coupling value.

[0155] The actual height calculation logic calculates the temperature compensation term based on the optimal digital signal from the temperature sensor, performs frequency analysis on the optimal digital signal from the vibration sensor through Fourier transform to identify abnormal vibration frequencies, calculates the vibration compensation term based on the abnormal vibration frequencies, and calculates the current mold installation height based on the estimated mold installation height, the temperature compensation term, and the vibration compensation term.

[0156] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press, characterized in that, The method includes: Sensor assemblies are installed at the elbow joint of the press, the mold contact surface, and the mold frame to collect real-time sensor data; The real-time sensor data is processed to generate the current mold mounting height. The current mold mounting height is compared with the preset height to determine whether the height needs to be adjusted. If height adjustment is required, the mold height can be adjusted using the height adjustment device; The processing of the real-time sensor data includes: Real-time sensor data is preprocessed to extract highly correlated signals and compensate for the correlation signals; The estimated installation height is calculated based on the height correlation signal, and the estimated installation height is compensated by the compensation correlation signal to calculate the current installation height. The preprocessing of real-time sensor data includes: Statistical analysis is performed on the digital signal, and an optimized signal value is calculated using an optimization function. This optimized signal value is then normalized. The formula for calculating the optimized signal value is as follows: ， in, Represents digital signals, Indicates the optimal value of the signal. Represents the variance of a digital signal. This represents the adjustment parameters of the optimization function. and These represent the weighting coefficients of a digital signal. Represents the noise characteristics of digital signals. This represents the scaling factor of the optimization function. This represents the deviation value of abnormal digital signal data. This represents the observed values ​​of digital signal anomaly data; The initial parameters of the Kalman filter are initialized using prior knowledge. The normalized optimized signal value is input into the Kalman filter, which then fine-tunes the initial parameters, calculates the tuning parameters, and outputs the optimal digital signal based on the tuning parameters. The optimal digital signals from the displacement sensor, pressure sensor, and angle sensor are labeled as highly correlated signals, while the optimal digital signals from the temperature sensor and vibration sensor are labeled as compensated correlated signals.

2. The method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press according to claim 1, characterized in that, The step of calculating the estimated height of the mold based on the height correlation signal includes: The displacement contribution value is calculated based on the optimal digital signal from the displacement sensor. The formula for calculating the displacement contribution value is as follows: ， in, Indicates the displacement contribution value. This represents the conversion coefficient of the displacement sensor. This represents the optimal digital signal of the displacement sensor installed at the elbow joint. denoted by , j represents a single displacement sensor mounted on the mold contact surface, and J represents the total number of displacement sensors mounted on the mold contact surface. This represents the optimal digital signal of the j-th displacement sensor installed on the mold contact surface. This represents the displacement weight value of the j-th displacement sensor installed on the mold contact surface. Indicates the compensation coefficient. This represents the optimal digital signal of the displacement sensor installed at the mold frame location. , and Indicates the weighting coefficient; The high coupling value is calculated based on the optimal digital signals from the pressure sensor and the angle sensor. Calculate the estimated height of the mold based on the displacement contribution value and the height coupling value. ,in, Indicates the estimated height of the mold assembly. This indicates a highly coupled value.

3. The method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press according to claim 1, characterized in that, The compensation of the estimated height of the mold assembly using the compensation-related signal includes: Calculate the temperature compensation term based on the optimal digital signal from the temperature sensor; The optimal digital signal of the vibration sensor is analyzed by Fourier transform to identify abnormal vibration frequencies, and vibration compensation terms are calculated based on the abnormal vibration frequencies. Based on the estimated mold assembly height, temperature compensation, and vibration compensation, the current mold assembly height is calculated. The formula for calculating the current mold assembly height is as follows: ， in, Indicates the current mold mounting height. Indicates the estimated height of the mold assembly. This indicates the temperature sensitivity coefficient of the press material. This indicates the abnormal temperature during the operation of the press, while T represents the normal operating temperature of the press. denoted by , which is the vibration compensation coefficient obtained through experimental calibration; z represents a single abnormal vibration frequency during the operation of the press; and Z represents the total number of abnormal vibration frequencies during the operation of the press. This represents the z-th abnormal vibration frequency. This indicates the standard vibration frequency of the press.

4. The method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press according to claim 1, characterized in that, The acquisition of real-time sensor data includes: Data acquisition: Analog signal data is acquired through sensors at various measurement locations. The analog signal data includes displacement, pressure, temperature, angle, and vibration information. Signal conditioning: Conditioning the analog signal data; Analog-to-digital conversion: Converting conditioned analog signal data into digital signals using an analog-to-digital converter.

5. The method for monitoring and adjusting the mold mounting height of a double-elbow-lever high-tonnage press according to claim 1, characterized in that, The method of adjusting the mold height via a height adjustment device includes: Calculate the height deviation value based on the current mold height and the preset height, and determine the adjustment direction based on the positive or negative value of the height deviation value. Calculate the adjustment amplitude through a step-by-step adjustment method. The controller sends control commands to the hydraulic cylinder based on the adjustment direction and the adjustment amplitude; According to the control command, the speed at which hydraulic oil enters the hydraulic cylinder is changed, and the height of the mold is adjusted by controlling the flow rate and pressure of the hydraulic oil. During the adjustment process, the actual position of the mold is monitored in real time, and the height is fed back to the controller. The controller compares the fed-back height with the preset height. If there is still a height difference, the adjustment amplitude is recalculated and the control command is updated. When the controller confirms that there is no height difference, it generates a stop command and locks the current mold position through the locking device.

6. A mold mounting height monitoring and adjustment system for a double-elbow-lever large-tonnage press, used to implement the mold mounting height monitoring and adjustment method for a double-elbow-lever large-tonnage press as described in any one of claims 1-5, characterized in that, The system includes a data acquisition module, a data processing module, a height calculation module, and a height adjustment module; The data acquisition module is used to install sensor components on the press and acquire analog signal data from each sensor. The data processing module is configured with a data processing strategy, which is used to convert analog signal data into digital signals, preprocess the digital signals, extract highly correlated signals, and compensate for correlated signals. The height calculation module is configured with a height calculation strategy. The height calculation strategy calculates the estimated height of the formwork based on the height-related signal, compensates the estimated height of the formwork based on the compensation-related signal, and calculates the current formwork height. The height adjustment module adjusts the mold mounting height of the press through a height adjustment device.

7. The mold mounting height monitoring and adjustment system for a double-elbow-lever high-tonnage press according to claim 6, characterized in that, The data processing module includes: The signal conversion unit is used to condition analog signal data and convert the conditioned analog signal data into digital signals through an analog-to-digital converter. The signal preprocessing unit is used to perform statistical analysis on the digital signal, calculate the optimized signal value through the optimization function, normalize the optimized signal value, output the optimal digital signal through the Kalman filter, mark the optimal digital signal from the displacement sensor, pressure sensor and angle sensor as highly correlated signal, and mark the optimal digital signal from the temperature sensor and vibration sensor as compensated correlation signal. The data processing strategy includes signal conversion logic and signal classification logic. The signal conversion logic is used to convert analog signal data into digital signals and is configured within the signal conversion unit. The signal classification logic is used to preprocess the digital signals, extract highly correlated signals and compensate for correlated signals, and is configured within the signal preprocessing unit.

8. The mold mounting height monitoring and adjustment system for a double-elbow-lever high-tonnage press according to claim 7, characterized in that, The height calculation module includes: The height estimation unit calculates the estimated height of the mold based on the optimal digital signals from the displacement sensor, pressure sensor, and angle sensor. A height compensation unit is used to calculate temperature compensation and vibration compensation, and to calculate the current mold installation height based on the estimated installation height, temperature compensation, and vibration compensation. The altitude calculation strategy includes altitude estimation logic and actual altitude calculation logic; The height prediction calculation logic calculates the displacement contribution value based on the optimal digital signal from the displacement sensor, calculates the height coupling value based on the optimal digital signals from the pressure sensor and the angle sensor, and calculates the estimated height of the mold based on the displacement contribution value and the height coupling value. The actual height calculation logic calculates the temperature compensation term based on the optimal digital signal of the temperature sensor, performs frequency analysis on the optimal digital signal of the vibration sensor through Fourier transform to identify abnormal vibration frequencies, calculates the vibration compensation term based on the abnormal vibration frequencies, and calculates the current mold installation height based on the estimated mold installation height, the temperature compensation term, and the vibration compensation term. The height prediction calculation logic is configured within the height prediction unit, and the actual height calculation logic is configured within the height compensation unit.

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