VCV take-up and pay-off rack automatic switching system and method

Abstract

The invention provides a VCV take-up and pay-off rack automatic switching system and method, and relates to the technical field of equipment control in a high-voltage cable crosslinking process, and the system comprises a main control electric cabinet and a human-computer interaction interface; the main control electric cabinet is integrated with a dual-power switch, an intermediate relay group arranged in an M * N matrix and a PLC (Programmable Logic Controller); the man-machine interaction interface is provided with M * N groups of switching buttons and corresponding indicating lamps, and is used for operating instruction input and state monitoring; wherein the PLC realizes the dynamic matching of any VCV production line and any take-up and pay-off rack by controlling the on-off of a coil of the intermediate relay, and only allows a single production line to establish exclusive connection with a single take-up and pay-off rack. According to the invention, the PLC controls the M * N matrix relay to realize automatic switching, manual wire dismounting and wiring are replaced, and the switching time is shortened from half a day to a minute level; according to fool-proof and interlocking logic, wiring error shutdown is avoided, dual-power redundancy and manual forced switching are reliable, a reserved slot supports production line capacity expansion, and efficiency and stability are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of equipment control in the cross-linking process of high-voltage cables, and in particular to a VCV reel mounting frame automatic switching system and method. BACKGROUND

[0002] In the field of high-voltage cable manufacturing, each vertical continuous vulcanization (VCV) production line needs to be equipped with a dedicated reel mounting frame for continuous conveying and winding of cable cores. In the traditional configuration, the VCV production line and the reel mounting frame adopt a one-to-one fixed matching mode (for example, three production lines correspond to three sets of reel mounting frames), and signal transmission is realized through physical wiring connection between the control boxes of the two parties.

[0003] With the expansion of production capacity, the number of VCV production lines in the factory often needs to be increased (for example, to five), but due to the layout of the workshop space and cost factors, the number of reel mounting frames cannot be increased synchronously (for example, still retaining three sets). At this time, dynamic matching of multiple reel mounting frames and multiple VCV production lines needs to be realized (such as 1# VCV matching 2# reel mounting frame, and next time switching to 1# VCV matching 1# reel mounting frame). However, the existing technology has the following serious defects: (1) Low efficiency of manual switching: each time the switching needs to be operated by personnel to remove the control line between the original VCV production line control box and the reel mounting frame, and then rewire to the new matched production line control box, and the single adjustment takes as long as half a day.

[0004] (2) High risk of operation: Frequent disconnection of the line can easily lead to wiring errors or poor contact, causing equipment failure to start or abnormal shutdown; Manual operation lacks error prevention mechanism, and electrical components may be damaged due to misconnection.

[0005] (3) Limited production flexibility: under the demand of dynamic matching, manual switching is difficult to quickly respond to changes in production scheduling, which restricts the improvement of production efficiency.

[0006] Therefore, it is urgent to develop a system that can automatically and reliably realize the dynamic switching and matching of VCV production lines and reel mounting frames to solve the efficiency, safety and flexibility bottlenecks of manual operation. SUMMARY

[0007] Therefore, the embodiments of the present application provide a VCV reel mounting frame automatic switching system and method to solve the problem of low efficiency of manual switching of the reel mounting frame and the problem of easily causing equipment abnormal shutdown due to wiring errors in the prior art.

[0008] To solve the above problems, the embodiments of the present application provide a VCV reel mounting frame automatic switching system, which comprises a main control cabinet and a man-machine interface; The main control cabinet integrates: Dual power supply switch, providing redundant power supply; MxN matrix arranged intermediate relay group for transferring VCV production line and control signal of the take-up and pay-off stand; PLC, controlling the on-off of the intermediate relay group through a logic program; The human-computer interaction interface is provided with MxN groups of switching buttons and corresponding indicator lights for operation instruction input and state monitoring; The PLC realizes dynamic matching of any VCV production line and any take-up and pay-off stand by controlling the on-off of the intermediate relay coil, and only allows single production line and single take-up and pay-off stand to establish exclusive connection.

[0009] Preferably, the intermediate relay group uses Schneider RX series relays, each relay is provided with a manual forced operating rod, and supports directly switching the contact state through mechanical structure when power is off.

[0010] Preferably, in the MxN matrix, M is the number of VCV production lines, M≥2, N is the number of take-up and pay-off stands, N≥2, and M>N, and each intermediate relay uniquely corresponds to the control line of one production line and one set of take-up and pay-off stand.

[0011] Preferably, the dual power supply switch is Schneider WATSN-4P100A model, two independent power input, and automatically switches to the standby power supply when any power supply is abnormal.

[0012] Preferably, the logic program of the PLC is built-in interlocking logic, which prohibits two production lines from being connected to the same take-up and pay-off stand at the same time, and the original connection must be released through the human-computer interaction interface before establishing a new connection.

[0013] Preferably, the logic program of the PLC contains a foolproof mechanism, the switching button needs to be triggered continuously for more than a set time threshold before it takes effect, and the human-computer interaction interface real-time feedback operation instruction state.

[0014] Preferably, the main control cabinet is provided with an expansion slot, and the number of production lines or take-up and pay-off stands can be expanded by adding relay modules.

[0015] Preferably, the human-computer interaction interface monitors the state of the dual power supply, the on-off state of the intermediate relay contact, and the current matching relationship, and dynamically displays through the indicator light group.

[0016] The embodiment of the application also provides a VCV take-up and pay-off stand automatic switching method, which is based on the VCV take-up and pay-off stand automatic switching system described above, and comprises the following steps: Step S1: selecting the VCV production line and take-up and pay-off stand combination to be released on the human-computer interaction interface; Step S2: long press the "OFF" button of the corresponding combination to a set time threshold, PLC control intermediate relay disconnect the original connection; Step S3: select a new VCV production line and a combination of wire rack in the man-machine interface; Step S4: long press the "ON" button of the corresponding combination to a set time threshold, PLC control intermediate relay close the new connection; Step S5: real-time verification of the connection state through the indicator light.

[0017] Preferably, in steps S2 and S4, if the button is released without reaching the set time threshold, the PLC immediately terminates the switching process and resets the timer From the above technical solutions, the present application has the following beneficial effects: (1) greatly improve the switching efficiency and reduce labor costs: in the prior art, the switching of VCV production line and wire rack needs manual disconnection and connection, which takes up to half a day, and depends on the operation of maintenance personnel. The present application realizes the automatic switching of production line and wire rack through the PLC and intermediate relay group in the main control cabinet. The operator only needs to long press the corresponding button in the man-machine interface to complete the switching. The switching time is shortened from "half a day" to minutes, and the production personnel can operate independently without the intervention of maintenance personnel, which significantly reduces the labor input and improves the production continuity and overall efficiency.

[0018] (2) eliminate the risk of wiring error and ensure stable operation of the equipment: in the prior art, manual disconnection and connection are prone to wiring errors or poor contact due to operational errors, causing abnormal shutdown of the equipment. The present application fundamentally avoids human operation risks through the preset PLC logic program (including interlocking and foolproof mechanism) and the automatic switching function of the intermediate relay group: the program prohibits two production lines from connecting to the same wire rack at the same time, and the original connection must be disconnected before establishing a new connection; at the same time, the button long press trigger mechanism (≥5 seconds) can prevent misoperation. Through electrical automatic control instead of manual wiring, the problem of equipment shutdown caused by wiring error is solved, and the stability of equipment operation is improved.

[0019] (3) Strengthen system reliability and scene adaptability, guarantee production continuity: the invention improves system reliability through double design: one is to use Schneider double power switch (WATSN-4P100A) to realize dual power supply redundancy, when any power supply is abnormal, it is automatically switched to standby power supply, avoid control cabinet power failure leading to system failure; Two is that the intermediate relay group adopts Schneider RX series relay with manual forced operating rod, when power failure or fault, it can be forced to switch through mechanical operation, ensure that it can still be operated in emergency state. In addition, the system supports the mixed matching of imported VCV production line and domestic take-up and pay-off reel, and the main control cabinet is reserved with expansion slot, which can adapt to more production lines or take-up and pay-off reels by adding relay module, adapt to the needs of workshop production line expansion and diversified production scene. BRIEF DESCRIPTION OF DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiments will be briefly described below. The features and advantages of the present application can be more clearly understood by referring to the drawings. The drawings are schematic and should not be understood as any limitation on the present application. Those skilled in the art can obtain other drawings according to these drawings without creative labor. Among them: Figure 1 The structure diagram of the VCV take-up and pay-off reel automatic switching system provided by the present application; Figure 2 The overall layout diagram of the VCV take-up and pay-off reel automatic switching system in the present application; Figure 3 The main view of the main control cabinet and the power line connection diagram of the take-up and pay-off reel in the present application; Figure 4 The combined arrangement diagram of the intermediate relay group in the main control cabinet in the present application; Figure 5 The coil wiring diagram of the intermediate relay matched with 3 sets of take-up and pay-off reels for 1 VCV in the intermediate relay combination in the present application; Figure 6 The normally open and normally closed point wiring diagram of the intermediate relay matched with 3 sets of take-up and pay-off reels for 1 VCV in the intermediate relay combination in the present application; Figure 7 The main control screen schematic diagram of the man-machine interface (touch screen) in the present application. DETAILED DESCRIPTION

[0021] To make the purposes, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0022] Embodiment one: in order to solve the problems of low efficiency of manual switching of the take-up and pay-off rack, and abnormal stop of equipment caused by wiring error in the prior art, as shown in Figure 1 The present application proposes an automatic switching system of VCV take-up and pay-off rack, which comprises a main control cabinet and a man-machine interface. The main control cabinet integrates: a double power switch to provide redundant power supply; an intermediate relay group arranged in an MxN matrix for transferring control signals of the VCV production line and the take-up and pay-off rack; a PLC to control the on-off of the intermediate relay group through a logic program; the man-machine interface is provided with MxN groups of switching buttons and corresponding indicator lights for operation instruction input and state monitoring; The PLC realizes dynamic matching of any VCV production line and any take-up and pay-off rack by controlling the on-off of the intermediate relay coil, and only allows single production line and single take-up and pay-off rack to establish exclusive connection.

[0023] From the above technical solution, the present application proposes an automatic switching system of VCV take-up and pay-off rack, which integrates a double power switch, an intermediate relay group arranged in an MxN matrix and a PLC in the main control cabinet, and is matched with a man-machine interface provided with MxN groups of switching buttons and corresponding indicator lights, to realize the technical solution innovation: the double power switch provides redundant power supply to ensure the continuous operation of the system, the intermediate relay group transfers the control signals of the VCV production line and the take-up and pay-off rack, and the PLC controls the on-off of the relay coil through the built-in logic program to realize dynamic matching of any production line and take-up and pay-off rack and only allow single exclusive connection. The operator can complete the switching operation and state monitoring through the man-machine interface. This scheme effectively solves the problems of low efficiency of manual switching (reduced from half a day to minutes) and abnormal stop of equipment caused by wiring error in the prior art, and improves the system reliability through the double power supply redundancy and the relay manual forced operation function. The reserved expansion slot supports line expansion, and adapts to the diversified production scene requirements.

[0024] The following will be described in combination with Figures 2 to 7The application is further described in detail. The embodiment takes the matching switching of 5 VCV production lines (M=5, numbered 1#VCV-5#VCV) and 3 sets of coiling and uncoiling racks (N=3, numbered 1#coiling and uncoiling rack-3#coiling and uncoiling rack) as an example, wherein M≥2, N≥2 and M>N, and the specific implementation mode of the application is described in detail.

[0025] The VCV coiling and uncoiling rack automatic switching system provided by the application comprises a main control cabinet and a man-machine interactive interface (touch screen).

[0026] In the embodiment, the main control cabinet adopts an imitation Weidu power distribution cabinet (size 100+2000×800×400), integrates the following core components, and realizes control signal relay and logic control: Dual power switch: provides redundant power supply to ensure continuous operation of the system; M×N matrix arranged intermediate relay group: relays the control signals of the VCV production lines and the coiling and uncoiling racks, and the embodiment is a 5×3 matrix; PLC: controls the on-off of the intermediate relay group through the built-in logic program to realize dynamic matching; Auxiliary components: including Schneider circuit breakers (iC65N-C10A / 2P, iC65N-C32A / 3P), MW switching power supply (EDR-120-24), wiring terminals, 5-core 32A dark installation aviation plug, etc., wherein the aviation plug is used to realize the quick plug-in connection of the VCV production line / coiling and uncoiling rack and the main control cabinet.

[0027] In the embodiment, the man-machine interactive interface adopts a Siemens touch screen (KTP700BasicPN), which is provided with 5×3 groups of switching buttons (including “ON” and “OFF” soft buttons) and corresponding indicator lights, and is used for operation instruction input and real-time state monitoring. The interface layout is as shown in Figure 7 .

[0028] In the embodiment, the dual power switch adopts Schneider WATSN-4P100A model, accesses two independent power supplies, automatically switches to the standby power supply when any power supply is abnormal, and ensures that the control system does not fail in the case of power failure of the main control cabinet. The output end of the dual power switch is connected to the MW switching power supply to provide stable 24V DC power supply for the system.

[0029] In the embodiment, the intermediate relay group is arranged in a 5×3 matrix, and Schneider RX series relays (RXM4AB2BD+RXZE1M4C) are used. Each relay uniquely corresponds to the control circuit of one production line and one set of coiling and uncoiling rack (for example, 1# relay corresponds to 1# VCV and 1# coiling and uncoiling rack, 2# relay corresponds to 1# VCV and 2# coiling and uncoiling rack, and so on).

[0030] The structure and connection relationship of each relay are as follows: The coil loop: one end of the relay coil is connected to the 24V output of the MW switch power supply, and the other end is connected to the output point of the PLC expansion module (6ES7222-1HH32-0XB0) to receive the on-off control signal of the PLC; The main contact loop: the normally open contact of the relay is connected in series in the control circuit of the VCV production line reserved control electrical box and the take-up reel control electrical box. When the coil is powered, the contact is closed, and the control signal is connected. The auxiliary feedback loop: the auxiliary normally open contact of the relay is connected to the PLC input module (6ES7221-1BF32-0XB0), which feeds back the on-off state of the contact to the PLC in real time.

[0031] In addition, each relay is configured with a manual forced operating rod to support direct switching of the contact state through mechanical structure when power is off (without coil power supply), realizing emergency operation.

[0032] In this embodiment, the PLC uses Siemens 1214CPLC (6ES7214-1HG40-0XB0), and the control program is compiled by Siemens BOP programming software. The core functions include: (1) Interlocking logic The program has a built-in interlocking mechanism to prevent two production lines from being connected to the same take-up reel at the same time, and the original connection must be removed before establishing a new connection. The specific implementation is as follows: An internal relay flag is set for each take-up reel. When the take-up reel is connected to a certain production line, the flag is set to "1", and its normally closed contact is disconnected from the control loop of other production lines and the take-up reel; For example, when the 1# take-up reel is connected to the 1# VCV, the 1# take-up reel flag is set to "1", and its normally closed contact in the 2# VCV-1# take-up reel control loop is disconnected, preventing the 2# VCV from being connected to the 1# take-up reel. Only when the original connection is removed (the flag is reset to "0") and the normally closed contact is restored to closed, can a new connection be established.

[0033] (2) Foolproof mechanism The program sets a foolproof mechanism. The switch button needs to be triggered continuously for more than a certain time threshold (5 seconds in this embodiment) to take effect: When the operator presses the HMI button, the PLC starts a timer. Only when the button is triggered for more than 5 seconds, the timer outputs a valid signal to trigger the relay switching; If the button is released before 5 seconds, the PLC immediately terminates the switching process and resets the timer.

[0034] In addition, the main control cabinet of the application reserves an expansion slot, which can support the expansion of the number of production lines (M) or the number of wire racks (N) (such as expanding from a 5x3 matrix to a 6x4 matrix) by adding Schneider RX series relay modules, PLC expansion modules, and aviation plug interfaces.

[0035] The man-machine interface monitors the following states in real time and dynamically displays them through the indicator light group: Dual power supply state (on-off and switching state of two power supplies); Intermediate relay contact on-off state (through auxiliary feedback signal); Current matching relationship (connection combination of production line and wire rack, indicating light on indicates connection established).

[0036] Five groups of 15 Schneider indicating lights (XB2BVB3LC) are installed below the touch screen of the main control cabinet, which correspond to the HMI interface buttons one by one, realizing synchronous display of physical state.

[0037] Example Two: The application provides a VCV wire rack automatic switching method, which is based on the VCV wire rack automatic switching system of the above-mentioned example one, and specifically includes the following steps: Step S1: Select the connection combination to be released The operator checks the current matching state on the man-machine interface and selects the VCV production line-wire rack combination to be released (such as 1# VCV and 2# wire rack).

[0038] Step S2: Release the original connection Press the "OFF" button corresponding to the combination for ≥5 seconds, and after the PLC detects the continuous trigger signal, control the corresponding relay coil to lose power, the normally open contact is disconnected, and the original control line is cut off; the man-machine interface indicator light is extinguished, and the feedback connection is released.

[0039] Step S3: Select a new connection combination Select a new VCV production line-wire rack combination (such as 3# VCV and 2# wire rack) on the man-machine interface, and the PLC checks whether the target wire rack is idle (flag is "0") through interlocking logic.

[0040] Step S4: Establish a new connection Press the "ON" button corresponding to the new combination for ≥5 seconds, and the PLC controls the corresponding relay coil to get power, the normally open contact is closed, and the new control line is connected; the man-machine interface indicator light is lit, and the connection is established.

[0041] Step S5: Verify the connection state The PLC confirms the relay contact closure through the auxiliary feedback loop, and the man-machine interface synchronously updates the indicator light state, completing the switching.

[0042] The VCV reel automatic switching method of the embodiment is based on the foregoing VCV reel automatic switching system, and therefore the specific embodiments in the VCV reel automatic switching method can be seen from the foregoing embodiment part of the VCV reel automatic switching system. In order to avoid redundancy, the foregoing will not be described again.

[0043] The application realizes the automatic switching of 5 VCV production lines and 3 sets of reel racks by the above structure and method, the switching time is shortened from half a day of traditional manual wiring to minutes, and the equipment downtime caused by wiring errors is completely avoided. The person skilled in the art can adjust the values of M and N according to the actual needs, and only the corresponding adjustment of the matrix size and program parameters can reproduce the application.

[0044] Obviously, the above embodiments are only examples for clear illustration, and are not a limitation on the embodiments. For those skilled in the art, other different forms of changes or variations can be made on the basis of the above description. It is not necessary and impossible to enumerate all the embodiments. The obvious changes or variations derived therefrom are still within the protection scope of the application.

Claims

1. A VCV reel changer automatic switching system, characterized by, The main control cabinet and a man-machine interface are included. The main control cabinet is integrated with: a dual power switch to provide redundant power supply; a matrix of M×N intermediate relays for transferring control signals between VCV production lines and coil racks; a PLC to control the on-off of the intermediate relay group through a logic program; the man-machine interface is provided with M×N groups of switching buttons and corresponding indicator lights for operation instruction input and state monitoring; wherein the PLC realizes dynamic matching between any VCV production line and any coil rack by controlling the on-off of the intermediate relay coils, and only allows single production line and single coil rack to establish exclusive connection.

2. The VCV reel changer automatic switching system of claim 1, wherein, The intermediate relay group uses Schneider RX series relays, each of which is equipped with a manual forced operating rod to support direct switching of contact state through mechanical structure when power is off.

3. The VCV reel auto-switching system of claim 1, wherein, In the M×N matrix, M is the number of VCV production lines, M≥2, N is the number of coil racks, N≥2, and M>N, each intermediate relay uniquely corresponds to the control line of one production line and one set of coil racks.

4. The VCV reel auto-switching system of claim 1, wherein, The dual power switch is Schneider WATSN-4P100A, with two independent power inputs, and automatically switches to the standby power supply when any power supply is abnormal.

5. The VCV reel auto-switching system of claim 1, wherein, The logic program of the PLC has interlocking logic to prevent two production lines from connecting to the same coil rack at the same time, and the original connection must be released through the man-machine interface before establishing a new connection.

6. The VCV reel auto-switching system of claim 1, wherein, The logic program of the PLC contains a foolproof mechanism, the switching button must be triggered continuously for more than a certain time threshold before it takes effect, and the man-machine interface real-time feedback operation instruction state.

7. The VCV reel auto-switching system of claim 1, wherein, The main control cabinet is provided with an expansion slot, which supports the expansion of the number of production lines or coil racks by adding relay modules.

8. The VCV reel auto-switching system of claim 1, wherein, The man-machine interface monitors the status of dual power supply, the on-off state of intermediate relay contacts and the current matching relationship, and dynamically displays through the indicator light group.

9. A VCV reel changer automatic switching method, characterized by, The method is based on the VCV coil rack automatic switching system according to any one of claims 1 to 8, comprising the following steps: Step S1: select the VCV production line and coil rack combination to be released on the man-machine interface; Step S2: press the "OFF" button of the corresponding combination for a set time threshold, and the PLC controls the intermediate relay to disconnect the original connection; Step S3: select a new VCV production line and coil rack combination on the man-machine interface; Step S4: press the "ON" button of the corresponding combination for a set time threshold, and the PLC controls the intermediate relay to close the new connection; Step S5: verify the connection state in real time through the indicator light.

10. The VCV reel auto-switching method of claim 9, wherein, In steps S2 and S4, if the button is released without reaching the set time threshold, the PLC will immediately terminate the switching process and reset the timer.

Images