Pressure self-adjusting feeding system of aluminum material shearing machine based on synchronous roller

Abstract

The application provides a synchronous roller-based pressure self-adjusting feeding system of an aluminum material shearing machine, relates to the technical field of aluminum material shearing machines, and adopts three synchronous rollers which are combined with a moving block, a pneumatic telescopic rod and a pressure sensor and installed in the installation groove on the surface of a rotating disc to form multi-point support and tension control of the aluminum material. A control console collects the extrusion force signals output by the pressure sensor in real time, combines the rotating disc angle output by an angle sensor, calculates the actual pressure value in the horizontal direction through a pressure decomposition algorithm, compares the actual pressure value with a preset tension threshold to generate an error signal, and drives the pneumatic telescopic rod to dynamically adjust the position of the synchronous rollers. When the error exceeds the set range, the servo motor can also be controlled to adjust the rotating disc angle to change the wrapping angle of the synchronous rollers to realize tension compensation. The tension of the aluminum material during conveying under complex working conditions is kept stable, the situations of slackening, wrinkling, deviation and over-tightening and breaking are avoided, and thus the stability during the conveying process of the aluminum material and the subsequent shearing precision are improved.

Description

Technical Field

[0001] This invention relates to the field of aluminum shearing machine technology, specifically to a pressure-adjustable feeding system for aluminum shearing machines based on synchronous rollers. Background Technology

[0002] In continuous shearing, slitting, and other processing of thin metal sheets such as aluminum or aluminum strips, a series of feeding processes, including unwinding, traction, guiding, and tension adjustment, are required before entering the shearing zone. Existing aluminum shearing machine feeding systems generally use fixed rollers or simple tension control mechanisms, controlling the conveying tension of the aluminum by manually setting the unwinding resistance and adjusting the spacing between the guide rollers.

[0003] The existing technology has the following technical problems when used:

[0004] Problem 1: Traditional unwinding tension control relies heavily on mechanical friction plates, mechanical springs, and single servo control methods. This cannot quickly adjust to real-time tension changes in the aluminum material during transport, leading to situations where the tension is too high or too low. Insufficient tension can cause the aluminum material to slack, wrinkle, or even deviate from its intended path; excessive tension can easily cause the material to stretch, deform, or even break.

[0005] Question 2: Although some shearing machines are equipped with multiple guide rollers and synchronous rollers, the pressure and position between these rollers are usually fixed and cannot be adaptively adjusted according to the actual stress state during equipment operation. This results in uneven tension of the material at different operating stages and different roll diameters, affecting the subsequent shearing accuracy.

[0006] Problem 3: Inability to achieve closed-loop regulation: In existing technologies, pressure detection and adjustment mechanisms often operate independently, lacking fusion calculations with multi-source data such as angle and position, thus failing to form a true closed-loop control. Faced with complex operating conditions, such as changes in unwinding speed, roll diameter, and guide angle adjustments, traditional systems struggle to calculate and compensate in real time, resulting in an unstable feeding process.

[0007] Question 4: Traditional structures often use a fixed guide angle, making it impossible to actively adjust the angle at which the rollers wrap around the aluminum material as needed. This makes it impossible to achieve ideal friction and tension control under certain working conditions, affecting the overall conveying stability and shearing quality. Summary of the Invention

[0008] To address the shortcomings of existing technologies, this invention provides a pressure-adjustable feeding system for aluminum shearing machines based on synchronous rollers, solving the following problems:

[0009] 1. Traditional aluminum feeding systems rely on mechanical structures and single servo control for tension control, which cannot achieve real-time and precise adjustment of aluminum tension, leading to problems such as material loosening, wrinkling, and breakage.

[0010] 2. In traditional feeding systems, the lack of a coordinated dynamic adjustment mechanism between multiple guide rollers and synchronous rollers leads to uneven tension distribution, affecting the stability of aluminum material conveying and shearing accuracy.

[0011] 3. In traditional feeding systems, the pressure, angle, and position of the guide rollers and synchronous rollers cannot be integrated to form real-time closed-loop control, making it difficult to cope with complex working conditions caused by changes in unwinding speed, roll diameter, and guide angle.

[0012] 4. In traditional feeding systems, the fixed angle of the synchronous roller limits the adjustment of the aluminum material's wrapping angle, affecting the friction and tension control between the roller and the material, and reducing the stability of the conveying system.

[0013] To achieve the above objectives, the present invention provides the following technical solution: a pressure self-regulating feeding system for an aluminum shearing machine based on synchronous rollers, comprising a shearing machine body, characterized in that: an unwinding machine is provided on one side of the shearing machine body; a fixed roller is provided in the middle of the shearing machine body; servo motors are provided on both sides of the shearing machine body; a control console is provided on one side of the servo motors on one side of the shearing machine body; two turntables are provided at the bottom of the fixed roller; each of the two turntables has three mounting slots on its surface and a rotating shaft on the other side of its surface; pneumatic telescopic rods are provided inside the three mounting slots on the surfaces of the two turntables; a moving block is provided at one end of each of the three pneumatic telescopic rods; an air pipe is provided on one side of each pneumatic telescopic rod; a mounting frame is provided between the moving block and the pneumatic telescopic rod; a pressure sensor is provided on the surface of the mounting frame; a mounting hole is provided on the surface of the moving block; a ball bearing is provided inside the mounting hole; three synchronous rollers are provided between the two turntables; and an angle sensor is provided on the inner wall surface of the shearing machine body.

[0014] Preferably, the shearing machine body is parallel to the unwinding machine. The fixed roller is located at the top of the shearing machine body near the unwinding machine, and both ends of the fixed roller are axially connected to the shearing machine body. The two servo motors are mirror images of the shearing machine body, and both servo motors are bolted to the shearing machine body. The two servo motors are located at the bottom of the fixed roller. The two servo motors, the angle sensor, and the unwinding machine are all connected to the control console via wiring.

[0015] Preferably, the two turntables are installed in a mirror image on the inner walls of both sides of the shearing machine body, and the positions of the turntables correspond one-to-one with the positions of the servo motors. Both rotating shafts are integrally formed with the turntables and penetrate through the inner wall of the shearing machine body and are keyed to the servo motors. The rotating shafts are axially connected to the shearing machine body, and the rotating shaft on one side of the turntable surface is sleeved with an angle sensor. The angle sensor is bolted to the shearing machine body.

[0016] Preferably, the two turntables are in the shape of a Reno triangle, and three mounting slots are arranged in a circumferential array on the surface of the two turntables. The pneumatic telescopic rods inside the mounting slots are all bolted to the turntables. The bottom surface of the mounting frame is mounted on the top surface of the pneumatic telescopic rod, and the top surface of the mounting frame is mounted on the bottom surface of the moving block. The pneumatic telescopic rod, the mounting frame, and the moving block are bolted together. The pressure sensors are all mounted on the mounting frame and are threaded to the mounting frame. One end of each pressure sensor abuts against the moving block. The moving block is connected to the pneumatic telescopic rod through the mounting frame.

[0017] Preferably, one end of each air pipe passes through the turntable and is connected to the pneumatic telescopic rod pipe inside the mounting groove on the surface of the turntable. The air pipe is made of silicone material. The ball bearings inside the mounting holes on the surface of the moving block are engaged with the moving block. The positions of the three synchronous rollers between the two turntables correspond one-to-one with the positions of the moving blocks inside the three mounting grooves on the surface of the turntable, and both ends of the synchronous rollers are inserted into the ball bearings inside the mounting holes on the surface of the moving block.

[0018] Preferably, the synchronous roller is installed in the ball bearing of the moving block in the mounting groove on the turntable surface, the pneumatic telescopic rod is connected to the moving block through the mounting bracket and located inside the mounting groove, the control console is electrically connected to the pneumatic telescopic rod, and the pneumatic telescopic rod can drive the moving block and the synchronous roller to change their radial position.

[0019] This invention provides a pressure-adjustable feeding system for an aluminum shearing machine based on synchronous rollers. It has the following beneficial effects:

[0020] 1. This technical solution achieves real-time tension detection and active adjustment of aluminum material during transmission by combining three synchronous rollers and their corresponding moving blocks – pneumatic telescopic rods – pressure sensors located in the middle of the shearing machine body. Unlike traditional mechanical friction plates and single servo systems, the system collects the contact pressure between the synchronous rollers and the aluminum material in real time during operation. The pressure sensor converts the detected pressure signal into an electrical signal and transmits it to the control console. The control console embeds a pressure adaptive adjustment algorithm, which compares the real-time pressure value with a preset tension threshold, generates an error signal, and outputs it to the pneumatic telescopic rod. The pneumatic telescopic rod automatically extends and retracts according to control commands, driving the moving blocks to change the position of the synchronous rollers, thereby adjusting the pressure applied by the synchronous rollers to the aluminum material. This ensures that the tension of the aluminum material is maintained within the preset range in real time, preventing slackness, wrinkles, deviation, excessive tension, and breakage.

[0021] 2. In this technical solution, the three synchronous rollers are not fixedly installed. Instead, they are installed by combining multiple mounting slots and moving blocks on the surface of the turntable. Each moving block is supported and driven by a pneumatic telescopic rod. The control console automatically controls the extension and retraction of the telescopic rod based on pressure feedback. The moving blocks cause slight changes in the radial position of the rollers, enabling dynamic adjustment of the contact pressure and position of the synchronous rollers on the aluminum material. The three synchronous rollers form an S-shaped feeding path with a reasonable wrapping angle. Through fine-tuning of three independent pressure channels, the stress state of each synchronous roller can be adaptively adjusted, ensuring that the aluminum material receives uniform tension at different operating stages and with different coil diameters, thereby improving the dimensional accuracy and surface quality of subsequent shearing.

[0022] 3. This technical solution features rotatable turntables on both sides inside the shearing machine body. These turntables are connected to servo motors via shafts and can rotate actively under control from the console. Three synchronous rollers are mounted in a circular array on the turntable surface. The angle at which the three rollers wrap around the aluminum material is adjustable as the turntable rotates. The console dynamically calculates the optimal wrapping angle based on angle data from angle sensors and pressure data from pressure sensors. When a tension deviation is detected that cannot be compensated for by simple pneumatic telescopic rod adjustment, an angle adjustment command is sent to the servo motor to change the turntable angle, optimizing the roller wrapping angle and friction distribution around the aluminum material. This results in more stable aluminum tension, further improving conveying smoothness and shearing accuracy. Attached Figure Description

[0023] Figure 1 This is a front view structural diagram of the shearing machine feeding system of the present invention;

[0024] Figure 2 This is a rear view structural diagram of the shearing machine feeding system of the present invention;

[0025] Figure 3 This is a top view schematic diagram of the shearing machine feeding system of the present invention;

[0026] Figure 4 For the present invention Figure 3 Sectional view at point AA;

[0027] Figure 5 For the present invention Figure 3 Sectional view at BB;

[0028] Figure 6 This is a schematic diagram of the turntable structure of the shearing machine feeding system of the present invention;

[0029] Figure 7 This is a schematic diagram of the feeding system of the shearing machine feeding system of the present invention.

[0030] The components include: 1. Shearing machine body; 2. Unwinding machine; 3. Control console; 4. Fixed roller; 5. Servo motor; 6. Turntable; 7. Synchronous roller; 8. Mounting slot; 9. Pneumatic telescopic rod; 10. Pressure sensor; 11. Moving block; 12. Mounting hole; 13. Ball bearing; 14. Air pipe; 15. Rotating shaft; 16. Angle sensor; 17. Mounting frame. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Specific Implementation Example 1:

[0033] like Figures 1 to 7 As shown, this invention proposes a pressure self-regulating feeding system for an aluminum shearing machine based on synchronous rollers, the structure of which and its operation mode are as follows:

[0034] The system includes a shearing machine body 1, an unwinding machine 2 located on one side of the shearing machine body 1, a fixed roller 4 located in the middle of the shearing machine body 1, servo motors 5 symmetrically arranged on both sides of the shearing machine body 1, a control console 3 located on one side of the servo motors 5, turntables 6 located on both sides inside the shearing machine body 1, a pneumatic telescopic rod 9 mounted on the turntable 6, a moving block 11, a ball bearing 13, a mounting groove 8, a synchronous roller 7, a pressure sensor 10, and an angle sensor 16 mounted on the rotating shaft 15.

[0035] In this pressure-adjustable feeding system for an aluminum shearing machine based on synchronous rollers, a close collaborative relationship is formed among the various components. Each component undertakes a specific function and has a corresponding working principle during system operation. The unwinding machine 2 is primarily responsible for fixing and controlling the release of the aluminum coil. The aluminum coil is securely mounted on the drum of the unwinding machine 2 via a tensioning shaft. The servo motor 5 on the unwinding machine 2 drives the drum to rotate, and an existing tension control mechanism is configured between the drum and the support structure of the unwinding machine 2. During the rotation of the drum, an adjustable damping torque is always provided so that the aluminum material is neither loosened nor over-tightened when it is released. The aluminum material is drawn along a preset path and enters the shearing machine body 1. Two opposing turntables 6 serve as the support and adjustment mechanism for the synchronous rollers 7. The turntables 6 are integrally formed by a rotating shaft 15 that penetrates the inner wall of the shearing machine body 1. The rotating shaft 15 is keyed to the servo motors 5 on both sides. Driven by the servo motors 5, the turntables 6 can rotate. The surface of the turntables 6 is in the shape of a Reichstag triangle. This geometry has the advantages of equal circumference and high space utilization. It is a triangle composed of three arcs with equal width, which facilitates the uniform distribution and space optimization of the synchronous rollers 7. The three synchronous rollers 7 are arranged at equal intervals, and it is convenient to install three mounting slots 8 on the circumferential array. Each mounting slot 8 is equipped with a pneumatic telescopic rod 9 and a moving block 11. The pneumatic telescopic rod 9 is equipped with an overload protection valve. When the pressure exceeds the upper limit set by the vertical operator, it automatically releases pressure to prevent the aluminum material from breaking or the equipment from being damaged. The pneumatic telescopic rod 9 is connected to an external air source through an air pipe 14. The air tube 14 is made of high-temperature resistant silicone material and its aging condition is checked every 6 months. The pressure sensor 10 and angle sensor 16 need to be calibrated every 12 months to ensure measurement accuracy. The pneumatic telescopic rod 9 is responsible for radial extension and retraction under the command of the control console 3, which drives the position of the moving block 11 to change. The surface of the moving block 11 is provided with mounting holes 12 and built-in ball bearings 13 for low-friction support of the synchronous rollers 7. The mounting slots 8 of the turntables on both sides correspond one-to-one with the positions of the synchronous rollers 7, forming three pairs of support points, so that the three synchronous rollers 7 can be dynamically adjusted relative to the aluminum material after the moving block 11 is finely adjusted. A mounting frame 17 is located between the moving block 11 and the pneumatic telescopic rod 9. Three synchronous rollers 7 are passively and synchronously rolled under the traction of the aluminum material. The rolling friction generates traction and maintains tension on the aluminum material. When the aluminum material exerts pressure on the synchronous rollers 7, this force is transmitted through the moving block 11 to the pressure sensor 10 mounted on the mounting frame 17 between the moving block 11 and the pneumatic telescopic rod 9. The pressure sensor 10 collects the pressure exerted by the moving block 11 in real time and converts it into an electrical signal, which is then fed back to the control console 3. A fixed roller 4 is mounted horizontally at the top of the shearing machine body 1, with its two ends shafted to the body. It further supports and guides the aluminum material, ensuring its stable posture and preventing deviation when entering the shearing area. An angle sensor 16 is mounted on the rotating shaft 15 of one side of the turntable 6, outputting the rotation angle θ of the turntable 6 in real time and transmitting the data to the control console 3 for subsequent calculations.The control console 3, as the core control unit of the system, is internally connected to the servo motor 5 of the unwinding machine 2, the servo motor 5 of the shearing machine, the pneumatic telescopic rod 9, the pressure sensor 10, and the angle sensor 16. During operation, it samples the signal output by the pressure sensor 10 at high speed. Through a pressure adaptive adjustment algorithm, it compares the collected pressure value with a preset tension threshold and calculates the error signal, which is then output to the actuator of the pneumatic telescopic rod 9. This causes the moving block 11 to adjust its position through the telescopic movement of the pneumatic telescopic rod 9, ensuring that the contact pressure of the synchronous roller 7 on the aluminum material returns to the preset tension range in real time. Simultaneously, when the servo motor 5 of the turntable 6 drives the turntable 6 to rotate, the angle sensor 16 outputs the angle θ in real time. The pressure decomposition algorithm in the control console 3 decomposes and calculates the oblique extrusion force signal collected by the pressure sensor 10 to obtain the actual pressure value along the horizontal direction. This value is then compared with the preset tension threshold to generate a new error signal, which controls the pneumatic telescopic rod 9 to perform compensation adjustment, ensuring that the tension applied to the aluminum material by the synchronous roller 7 remains stable within the preset range regardless of the turntable 6's angle. Through this multi-component linkage, the unwinding machine 2 is responsible for stable feeding, the turntable 6 and synchronous roller 7 realize aluminum material traction and pressure sensing, the pneumatic telescopic rod 9 is responsible for dynamic adjustment, the pressure sensor 10 and angle sensor 16 provide real-time data, and the control console 3 performs logical calculations and outputs control commands based on the collected data. Ultimately, it realizes the smooth conveying, tension adaptive adjustment and state control of aluminum material in the entire conveying process, thereby providing a reliable guarantee for the subsequent shearing process.

[0036] The main function of angle sensor 16 is to monitor the rotation angle θ of turntable 6 in real time. Angle sensor 16 is coaxially fixed to the turntable 6 shaft 15 via a high-precision sleeve, using a gapless key connection to ensure no mechanical vibration during measurement. Angle data is transmitted to console 3 via a shielded cable to reduce electromagnetic interference. Console 3 has a built-in sensor fault detection module. The alarm device mainly receives the following key sensor and system status signals as input data through console 3: Pressure sensor 10 data: The sensor collects the extrusion pressure of moving block 11 in real time and converts the pressure signal into an electrical signal, which is then input to console 3 after analog-to-digital conversion. The pressure data includes the current pressure value and the rate of pressure change, facilitating the identification of abnormally high or low pressure states. Angle sensor 16 data: Angle sensor 16 outputs real-time data of the rotation angle θ of turntable 6, which is also input through the data acquisition module of console 3. The angle information is used to calculate pressure decomposition and assist in determining whether the tension is within the normal range. Sensor status signals: These include the sensor's own health status indication, i.e., open circuit, short circuit, over-range alarm, and communication status, providing real-time feedback on whether the sensor is working properly. Actuator feedback signals: Position feedback signals from the pneumatic telescopic rod 9 and servo motor 5 indicate whether the actuators act according to instructions and whether there is any jamming or abnormality. System operating status: Includes the operating status of the console 3 software, communication link status, power supply status, etc., serving as auxiliary inputs to judge the overall health status of the equipment. The alarm device's built-in microprocessor performs real-time monitoring and logical judgment of input data. The specific processing includes: comparing pressure and angle data with preset thresholds to identify whether they exceed the safe range; monitoring sensor status signals, and determining sensor failure by detecting open circuits, short circuits, or abnormal fluctuations; detecting abnormalities in actuator feedback signals, such as prolonged inactivity or abnormal position deviations; judging whether there are software crashes, communication disconnections, or other faults based on the system operating status. When any input indicator abnormally reaches the alarm condition, the alarm device immediately generates an alarm signal. The alarm device outputs alarm information in multiple ways to ensure timely reminders to operators and linkage protection measures: Local audible and visual alarms emit continuous alarm sounds through a buzzer and simultaneously illuminate a red alarm indicator light to prompt on-site operators to pay immediate attention. The console 3 display screen displays alarm prompts.

[0037] Specific alarm information, including alarm type, location of faulty component, and suggested operation, is displayed on the touchscreen or indicator panel of console 3. Digital signal output triggers linked protection actions of external devices via digital interface, such as emergency shutdown and air supply cutoff. Alarm data packets, containing alarm codes, timestamps, and real-time values ​​of relevant sensors, are sent to the host computer and monitoring system via CAN bus or MODBUS protocol for convenient remote monitoring and data recording. Angle sensor 16 feeds back the rotation angle of turntable 6 to console 3, providing the system with accurate turntable 6 position information. The data from angle sensor 16 is crucial for the system's pressure regulation. Since the tension of synchronous roller 7 is affected by the rotation angle of turntable 6, angle sensor 16 helps console 3 calculate the impact of turntable 6 angle changes on the pressure of the aluminum material. When turntable 6 rotates a certain angle, the contact pressure of the aluminum material shifts. Console 3 uses the data from angle sensor 16, combined with the pressure signal output from pressure sensor 10, to perform pressure decomposition, ensuring that even if the turntable 6 angle changes, the system can still adjust the tension of synchronous roller 7 in real time to maintain a stable tension value for the aluminum material. When the turntable 6 rotates, the angle sensor 16 provides real-time angle feedback to the system. The control console 3 automatically adjusts the pneumatic telescopic rod 9 according to the angle change, thereby fine-tuning the position of the synchronous roller 7 to ensure that the contact pressure between the synchronous roller 7 and the aluminum material remains within the preset tension range. The pneumatic telescopic rod 9 is controlled by a proportional solenoid valve. The valve opening is adjusted by the analog current signal output by the control console 3 to achieve fine adjustment of the air pressure. The air source is processed by a pressure regulator and filter to ensure stable air pressure and no impurities. The control system adopts a closed-loop control strategy, providing real-time feedback on the position and force of the telescopic rod to ensure high response speed and accuracy of the telescopic action, thereby achieving precise adjustment of the position of the moving block 11 and real-time control of the contact pressure between the synchronous roller 7 and the aluminum material. The feedback from the angle sensor 16 ensures that the pressure adjustment is accurate at any angle, avoiding tension instability caused by changes in the angle of the turntable 6. The angle sensor 16 is usually installed on the rotating shaft 15 of the turntable 6. This rotating shaft 15 runs through the inner wall of the entire shearing machine body 1, connects to the servo motors 5 on both sides, and directly drives the turntable 6 to rotate. An angle sensor 16 mounted on the rotating shaft 15 can directly sense the rotation angle of the turntable 6 without interference from other mechanical movements, ensuring accurate measurement. The angle sensor 16 provides feedback data by measuring the rotation angle of the rotating shaft 15, and this data is transmitted to the control console 3 in real time. The angle sensor 16 in this application can also be a rotary encoder, potentiometer, or Hall effect sensor, which acquires changes in the rotation angle in different ways and converts them into electrical signals that are transmitted to the control console 3. The angle sensor 16 mounted on the rotating shaft 15 rotates synchronously with the turntable 6, avoiding interference from other external factors on the angle measurement. It can accurately reflect the rotation state of the turntable 6, enabling precise closed-loop control between the feedback of angle changes and pressure regulation.The control console 3 utilizes the rotation angle θ data output by the angle sensor 16, combined with real-time data from the pressure sensor 10, to perform a pressure decomposition algorithm calculation. This algorithm decomposes the oblique pressure signal into actual horizontal pressure values, and adjusts the pneumatic telescopic rod 9 based on this data to ensure that the tension of the synchronous roller 7 remains stable within a preset range. Since the angle sensor 16 provides high-precision angle data for the turntable 6, it is crucial for the stability of the entire system. Even a slight change in angle can affect the tension applied by the synchronous roller 7. Through real-time feedback, the control console 3 can precisely adjust the pressure of the synchronous roller 7 during the rotation of the turntable 6, ensuring that the tension of the aluminum material is not disturbed by changes in the turntable 6's angle. The angle sensor 16 not only provides angle feedback but also enhances the system's adaptability to dynamic changes. If the turntable 6 needs to change its angle due to the characteristics of the aluminum material or other operational requirements, the system can adjust in real-time based on the data from the angle sensor 16, ensuring that the tension of the aluminum material remains stable regardless of the angle.

[0038] In operation, the unwinding machine 2 secures the aluminum coil via a tensioning shaft. The unwinding machine 2 is arranged parallel to the shearing machine body 1. The rotation of its drum is driven by a servo motor 5 on the unwinding machine 2. A tension control mechanism generates an adjustable damping torque during drum rotation, ensuring that the aluminum material is neither too loose nor too tight when released. During operation, the aluminum material is drawn out from the outside of the drum along a preset feeding path and passes sequentially through three synchronous rollers 7 located between two opposing turntables 6 inside the shearing machine. The three synchronous rollers 7 are arranged in a circumferential array, with their relative positions being upper, middle, and lower. They are rotatably mounted in the mounting holes 12 of the moving block 11 via ball bearings 13. The moving block 11 is supported and fixed in three mounting slots 8 on the surface of the turntable 6 by a pneumatic telescopic rod 9. The surface of the synchronous rollers 7 is coated with wear-resistant rubber, balancing a high coefficient of friction with protection of the aluminum surface, preventing scratches or indentations. The hardness of the rubber layer is specially adjusted to ensure sufficient traction while minimizing surface damage. Regularly check the wear condition of the rubber surface and replace it in time when necessary to maintain a stable tension control effect. The ball bearing 13 of the synchronous roller 7 adopts a closed-seal structure and is pre-filled with high-performance grease to reduce maintenance frequency. It is recommended to check for grease replenishment every 6 months to ensure adequate bearing lubrication and prevent increased friction and abnormal operation due to insufficient lubrication. Regularly check the bearing temperature and vibration condition, and replace it in time if abnormalities are found to ensure long-term stable operation of the equipment. The turntable 6 is in the shape of a Reno triangle and is integrally formed by the rotating shaft 15, which runs through the inner wall of the shearing machine body 1 and is connected to the servo motors 5 on both sides. One side of the turntable 6 has an angle sensor 16 sleeved on the rotating shaft 15 for real-time output of the rotation angle θ of the turntable 6.

[0039] After passing through three synchronous rollers 7, the aluminum material continues to pass through a fixed roller 4 located at the top of the shearing machine body 1. The fixed roller 4 is horizontally installed with its two ends axially connected to the shearing machine body 1, and is used to further support and guide the aluminum material, so that the aluminum material enters the shearing area at a stable angle.

[0040] Upon system startup, console 3, acting as the core control unit, first initiates the coordinated startup of the multi-source actuators. Console 3 has pre-set startup logic; when the operator issues a startup command via the control interface, console 3 immediately sends a startup signal to the servo motor 5 of the unwinding machine 2. Upon receiving the signal, the servo motor 5 drives the drum to rotate, ensuring that the aluminum release speed is neither too fast nor too slow, preventing slack, breakage, or kinking, thus achieving stable and controlled unwinding output. Simultaneously, console 3 also sends a synchronous startup signal to the servo motor 5 connected to the transmission wheel inside the shearing machine body 1. After starting, the transmission wheel servo motor 5 drives the transmission wheel to rotate. The transmission wheel and the aluminum surface achieve positive traction through friction, continuously pulling the aluminum released from the unwinding machine 2 into the shearing machine, forming a stable conveying speed.

[0041] During this process, the rotational speeds of the servo motor 5 of the unwinding machine 2 and the servo motor 5 of the transmission wheel are coordinated in real time by the control console 3, ensuring precise synchronization between the unwinding speed and the winding speed of the transmission wheel. Through this linkage control, the unwinding machine 2 continuously releases aluminum material under controlled conditions, while the transmission wheel provides constant traction. The two form a dynamic balance system, ensuring stable tension and smooth conveying of the aluminum material during transmission, without slippage, material accumulation, or breakage. This lays a reliable operational foundation for the subsequent tension adjustment and shearing operations of the synchronous rollers 7. When the aluminum material is conveyed smoothly, it passes through the three synchronous rollers 7 in the middle of the turntable 6. The aluminum material passes through the bottom synchronous roller 7, the middle synchronous roller 7, and the top synchronous roller 7 in an S-shape, and finally passes through the fixed roller 4. Specifically, after being released from the unwinding machine 2, the aluminum material first passes through the bottom synchronous roller 7, then moves upwards, then through the middle synchronous roller 7, and finally through the top synchronous roller 7, forming an "S" shaped trajectory. The fixed roller 4 is horizontal with the transmission wheel of the shearing machine body 1, so that the transmission wheel pulls the aluminum material smoothly through the shearing area of ​​the shearing machine. When the aluminum material is conveyed, the three synchronous rollers can not only fix and support the aluminum material, but also generate traction when the aluminum material is conveyed, so that the three synchronous rollers 7 are passively and synchronously rolled under the traction of the aluminum material. When the aluminum material pulls the synchronous rollers 7, the extrusion force generated by the aluminum material on the three synchronous rollers 7 is transmitted to the pressure sensor 10 through the moving block 11. The pressure sensor 10 transmits the detected pressure signal to the control console 3 in real time.

[0042] The console 3 internally incorporates an adaptive pressure adjustment algorithm and a pressure decomposition algorithm, both developed in C language and running on an embedded real-time operating system. The console 3 employs a 32-bit embedded microcontroller equipped with X MB of flash memory and Y MB of RAM, supporting a real-time operating system for multi-threaded concurrent processing. The software runs a self-developed control logic program, including pressure sampling, angle calculation, tension error judgment, and actuator driving, employing a modular design for easy maintenance and upgrades. The system supports CAN bus and the MODBUS industrial standard communication protocol, enabling high-speed and stable communication with the host computer, sensors, servo drivers, and other peripheral devices. The CAN bus is used for high-speed data transmission between pressure sensor 10 and angle sensor 16, while the MODBUS protocol is used for data interaction with the host computer or external devices. The console 3 dynamically adjusts the data sampling period for pressure sensor 10 and angle sensor 16 according to the aluminum conveying speed and material characteristics, adaptively adjusting based on material type and operating conditions to ensure high-precision, high-response tension control even under high-speed aluminum conveying and complex state changes. All calculations are performed independently on the local machine, without relying on external servers, ensuring the system's independent operation and anti-interference capabilities in industrial settings. The control console 3 samples the pressure data output by the pressure sensor 10 at high speed. The tension threshold can be manually set via the control interface or automatically learned and optimized based on historical operating data and material characteristics to adapt to the tension requirements of different batches of aluminum. Based on the preset tension threshold and pressure change trend, the pressure error between the synchronous roller 7 and the aluminum is calculated, and an error signal is generated and output as an adjustment parameter to the pneumatic telescopic rod 9 actuator. Upon receiving the command, the pneumatic telescopic rod 9 extends and retracts, causing a fine adjustment in the position of the moving block 11. This, in turn, causes the synchronous roller 7 to change its contact pressure with the aluminum radially, ensuring that the tension of the synchronous roller 7 on the aluminum returns to the preset range in real time, achieving closed-loop tension regulation.

[0043] In the entire system, the unwinding machine 2, the shearing machine body 1, two servo motors 5, the turntable 6, the synchronous roller 7, the moving block 11, the pneumatic telescopic rod 9, the pressure sensor 10, and the angle sensor 16 form a highly efficient closed-loop control network through the control console 3. The unwinding machine 2 is responsible for the controlled release of the aluminum material. The synchronous roller 7 of the shearing machine pulls the aluminum material through friction and adjusts the tension through pressure feedback. The angle sensor 16 provides angle feedback to the turntable 6, the pressure sensor 10 provides real-time pressure data, and the control console 3 samples and processes the signals from each channel, outputting execution signals to the pneumatic telescopic rod 9 and the servo motors 5 to achieve real-time system adjustment. Specific Implementation Example 2:

[0045] like Figures 1 to 7 As shown, based on the content of the above specific embodiments, the following content is further disclosed:

[0046] The tension adjustment process in this technical solution is a closed-loop control system centered on the control console 3. The unwinding machine 2 continuously releases aluminum material, and the shearing machine pulls the aluminum material forward through the synchronous rollers 7; the control console 3 collects pressure and angle data in real time, determines whether to adjust solely through the pneumatic telescopic rod 9 based on the pressure deviation, and, if necessary, coordinates with the turntable 6 for position correction.

[0047] Turntable 6 remains stationary during normal operation. Only when control console 3 determines that simple roller fine-tuning is insufficient to return the tension to the set value will it drive servo motor 5 to rotate turntable 6 at a certain angle. This increases or decreases the wrapping angle of the aluminum material and changes the force direction of the synchronous roller 7, making tension control more diverse and precise. The wrapping angle is the arc range of the contact area between the aluminum material and the synchronous roller 7.

[0048] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising a reference structure" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0049] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A pressure-adjustable feeding system for an aluminum shearing machine based on synchronous rollers, comprising a shearing machine body (1), characterized in that: A winding machine (2) is provided on one side of the shearing machine body (1). A fixed roller (4) is provided in the middle of the shearing machine body (1). Servo motors (5) are provided on both sides of the shearing machine body (1). A control console (3) is provided on one side of the servo motor (5) on one side of the shearing machine body (1). Two turntables (6) are provided at the bottom of the fixed roller (4). Three mounting grooves (8) are provided on the surface of each of the two turntables (6), and a rotating shaft (15) is provided on the other side of each of the two turntables (6). Pneumatic telescopic rods (9) are provided inside the three mounting grooves (8) on the surface of each of the two turntables (6). A moving block (11) is provided at one end of each of the three pneumatic telescopic rods (9). An air pipe (14) is provided on one side of each of the pneumatic telescopic rods (9). A mounting frame (17) is provided between the moving block (11) and the pneumatic telescopic rod (9). A mounting frame (17) is provided on the surface of each of the mounting frames (17). The pressure sensor (10) and the moving block (11) are provided with mounting holes (12) on their surfaces. The mounting holes (12) are provided with ball bearings (13) inside. Three synchronous rollers (7) are provided between the two turntables (6). An angle sensor (16) is provided on the inner wall surface of the shearing machine body (1). The rotating shaft (15) on the surface of one turntable (6) is sleeved with the angle sensor (16). One end of the pressure sensor (10) abuts against the moving block (11). The moving block (11) is connected to the pneumatic telescopic rod (9) through the mounting bracket (17). The positions of the three synchronous rollers (7) between the two turntables (6) correspond one-to-one with the positions of the moving block (11) inside the three mounting grooves (8) on the surface of the turntable (6). Both ends of the synchronous rollers (7) are inserted into the ball bearings (13) inside the mounting holes (12) on the surface of the moving block (11).

2. The pressure self-regulating feeding system for an aluminum shearing machine based on synchronous rollers according to claim 1, characterized in that: The shearing machine body (1) is parallel to the unwinding machine (2). The fixed roller (4) is located on the top of the shearing machine body (1) near the unwinding machine (2), and both ends of the fixed roller (4) are axially connected to the shearing machine body (1). The two servo motors (5) are mirror images of the shearing machine body (1) and are bolted to the shearing machine body (1). The two servo motors (5) are located at the bottom of the fixed roller (4). The two servo motors (5), the angle sensor (16), and the unwinding machine (2) are all connected to the control console (3) via wiring.

3. The pressure self-regulating feeding system for an aluminum shearing machine based on synchronous rollers according to claim 1, characterized in that: The two turntables (6) are installed in a mirror image on the inner walls of the shearing machine body (1) on both sides, and the positions of the turntables (6) correspond one-to-one with the positions of the servo motors (5). The two rotating shafts (15) are integrally formed with the turntables (6), and the rotating shafts (15) penetrate the inner wall of the shearing machine body (1) and are keyed to the servo motors (5). The rotating shafts (15) are axially connected to the shearing machine body (1), and the angle sensor (16) is bolted to the shearing machine body (1).

4. The pressure self-regulating feeding system for an aluminum shearing machine based on synchronous rollers according to claim 1, characterized in that: The two turntables (6) are in the shape of a Reno triangle, and three mounting slots (8) are arranged in a circular array on the surface of the two turntables (6). The pneumatic telescopic rods (9) inside the mounting slots (8) are all bolted to the turntables (6). The bottom surface of the mounting frame (17) is mounted on the top surface of the pneumatic telescopic rod (9), and the top surface of the mounting frame (17) is mounted on the bottom surface of the moving block (11). The pneumatic telescopic rod (9), the mounting frame (17) and the moving block (11) are bolted together. The pressure sensors (10) are all mounted on the mounting frame (17), and the pressure sensors (10) are threaded to the mounting frame (17).

5. The pressure self-regulating feeding system for an aluminum shearing machine based on synchronous rollers according to claim 1, characterized in that: One end of each air pipe (14) passes through the turntable (6) and is connected to the pneumatic telescopic rod (9) pipe inside the mounting groove (8) on the surface of the turntable (6). The air pipe (14) is made of silicone material. The ball bearings (13) inside the mounting holes (12) on the surface of the moving block (11) are engaged with the moving block (11).

6. The pressure self-regulating feeding system for an aluminum shearing machine based on synchronous rollers according to claim 1, characterized in that: The synchronous roller (7) is installed in the ball bearing (13) of the moving block (11) in the mounting groove (8) on the surface of the turntable (6). The pneumatic telescopic rod (9) is connected to the moving block (11) through the mounting bracket (17) and is located inside the mounting groove (8). The control console (3) is electrically connected to the pneumatic telescopic rod (9). The pneumatic telescopic rod (9) can drive the moving block (11) and the synchronous roller (7) to change their radial position.

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