Control method for wire unwinding and warehousing

Abstract

The invention relates to the field of steel production, in particular to a control method for wire coil unloading and warehousing, which comprises the following steps: coil unloading control: a coil unloading trolley supports a wire coil and advances on a track, and the head position A11 of a first coil is calculated; calculating the head position A12 of the second coiling coil; and calculating the head position A1n of the nth coil. The automatic coil stripping device has the advantages that key parameters such as the position, the distance and the length of the wire coil can be accurately detected through the distance detection sensor and the photoelectric correlation detection sensor, so that accurate positioning and measurement of the wire coil are realized, errors caused by manual visual judgment are avoided, and the accuracy of coil stripping operation is improved; according to the measured distance value, the coil unloading position of each wire coil can be accurately determined by applying a calculation formula, it is ensured that the appropriate distance is kept between the wire coils, the problem that the ends of the coils are scratched due to the fact that the distance is too small is solved, and the stability of product quality is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of steel production, and particularly relates to a control method for wire rod uncoiling and storage. BACKGROUND

[0002] In the production process of wire rod products, the uncoiling and storage link as the last process of the production process is of great significance to guarantee production efficiency and maintain product quality. The traditional wire rod factory generally uses manual operation of the uncoiling trolley to carry out uncoiling and storage operation, which mainly has the following problems:

[0003] 1. Lack of operation accuracy

[0004] Some workshops use manual operation of the uncoiling trolley, which completely relies on workers to visually judge the spacing between wire rod coils and manually operate the movement and parking of the uncoiling trolley. This operation method lacks accuracy and often leads to too small spacing between wire coils.

[0005] 2. End of coil is easily damaged

[0006] When the spacing between wire coils is too small, the end of the wire coil is easily scratched during subsequent lifting and transporting, resulting in surface damage. This not only affects the appearance quality of the wire rod, but also may have adverse effects on its performance, thereby causing quality disputes.

[0007] 3. Frequent quality problems

[0008] Due to the difficulty of the operator to ensure that each uncoiling operation can maintain sufficient uncoiling spacing, the product quality is unstable and quality disputes frequently occur.

[0009] 4. Low efficiency and safety

[0010] The manual operation of the uncoiling trolley is low in efficiency and prone to operation errors, increasing the labor intensity of workers. At the same time, frequent manual operation also has certain safety hazards.

[0011] Although there are some automatic uncoiling devices in the prior art, they have the problems of imperfect function or low intelligentization degree:

[0012] Patent publication No. CN215974183U discloses "a full-automatic uncoiling device for rolled steel wire rod", which fixes the wire rod coil through a clamping mechanism to improve work efficiency and safety, but lacks precise control and adjustment function for the spacing between wire coils.

[0013] In summary, the traditional manual operation of uncoiling and storage cannot meet the requirements of modern wire rod production for high efficiency, high quality and high safety. SUMMARY

[0014] The application aims to provide a control method for wire coil unloading and storage, to solve the problems of low accuracy, product damage caused by improper control of wire coil spacing, low operation efficiency and poor safety caused by manual operation in the prior art.

[0015] To achieve the above-mentioned purpose, the application realizes the technical scheme as follows:

[0016] A control method for wire coil unloading and storage, based on the cooperative work of distance detection sensors and measurement sensors, the wire coil unloading and storage is completed through a PLC system, specifically comprising:

[0017] S1, equipment initialization inspection;

[0018] S2, unloading control:

[0019] The unloading trolley lifts the wire coil and advances on the track, and the head position A 11 of the first wire coil is calculated as follows:

[0020] A 11 =S 11 +a①;

[0021] L1=S 21 -S 11 ②;

[0022] In formulas ① and ②, S 11 represents the detection value of the distance detection sensor when the head of the first wire coil reaches the measurement sensor; a represents the distance from the head position A 11 of the first wire coil to the distance sensor, and the value of a is greater than 5 times the maximum wire coil length; S 21 represents the detection value of the distance detection sensor when the tail of the first wire coil reaches the measurement sensor; and L1 represents the length of the first wire coil.

[0023] The calculation formula of the head position A 12 of the second wire coil is as follows:

[0024] A 12 =S 12 +a-L1-m③;

[0025] L2=S 22 -S 12 ④;

[0026] In formulas ③ and ④, S 12 represents the detection value of the distance detection sensor when the head of the second wire coil reaches the measurement sensor; m represents the wire coil spacing; S 22 represents the detection value of the distance detection sensor when the tail of the second wire coil reaches the measurement sensor; and L2 is the length of the second wire coil.

[0027] Head position A of the nth coil 1n The calculation formula is as follows:

[0028] A 1n =S 1n +a-L1-L 2-。。。- L n-1 -m (n-1) ⑤;

[0029] L n =S 2n -S 1n ⑥;

[0030] In the formula ⑤ and ⑥, S 1n represents the detection value of the detection sensor when the head of the nth coil reaches the measurement sensor; S 2n represents the value of the detection sensor when the tail of the second coil reaches the measurement sensor; L n-1 represents the winding length of the (n-1)th coil;

[0031] Wherein, the value of n is determined by the length of the winding hoist magnet and the multiple of the coil, when the length of the hoist magnet is 3 times the length of the coil, n is equal to 3; when the length of the hoist magnet is 4 times the length of the coil, n is equal to 4.

[0032] In S1, the equipment initialization check includes:

[0033] The uncoiling trolley is in the initial position;

[0034] The value displayed by the distance detection sensor matches the actual value, there is no obstruction in the detection range of the measurement sensor, and the corresponding indicator light changes when the measurement sensor is blocked.

[0035] The uncoiling operation includes the following contents:

[0036] Select the uncoiling trolley;

[0037] The corresponding uncoiling trolley continuously uncoils, and after the uncoiling table is full and the crane is hoisted away, the next round of automatic uncoiling is carried out.

[0038] The distance detection sensor is used to measure the running position of the uncoiling trolley; the measurement sensor is used to measure the position of the coil on the uncoiling trolley.

[0039] Compared with the prior art, the beneficial effects of the present application are:

[0040] 1、Through the distance detection sensor and the photoelectric opposite detection sensor, the key parameters of the wire coil, such as the position, the interval and the length, can be accurately detected, so that the accurate positioning and measurement of the wire coil are realized, the error caused by manual visual judgment is avoided, and the accuracy of the uncoiling operation is improved; according to the measured distance value, the uncoiling position of each wire coil can be accurately determined by using a calculation formula, the appropriate interval between the wire coils is ensured, the problem of scratch on the end of the coil caused by too small interval is prevented, and the stability of the product quality is improved;

[0041] 2、With the help of the detection and PLC system, the scratch on the end of the wire coil during the uncoiling and hoisting process is effectively avoided, the appearance quality and performance of the wire are ensured, the risk of quality dispute caused by surface damage is reduced, the reputation and customer satisfaction of the enterprise are maintained; due to the significant improvement in the accuracy and consistency of the uncoiling operation, the quality of each wire coil is more stable and reliable, and the quality fluctuation caused by unstable operation is reduced;

[0042] 3、The system has the function of adjusting the interval between the coils, the operator can set the interval between the coils through the operation screen according to different specifications of the wire coil, reduces the direct contact between the operator and the equipment, saves the time and workload of adjusting the interval between the coils, further improves the production efficiency, and reduces the risk of time waste and production delay caused by improper manual adjustment;

[0043] 4、In the past, the operator needs to concentrate for a long time to visually judge and operate when manually controlling the uncoiling trolley, and the labor intensity is large; in the present application, the operator only needs to perform simple operation of necessary monitoring and parameter setting, which greatly reduces the labor intensity; reduces the direct contact and frequent operation between the operator and the equipment, reduces the risk of work accidents caused by manual operation errors, provides a safer working environment for the production site, and meets the requirements of modern enterprise safety production;

[0044] 5、For wire coils of different specifications, the operator only needs to simply set the relevant parameters through the operation screen, and the PLC system can adjust the uncoiling mode and the interval between the coils, which realizes good adaptability to various specifications of products, without the need for large-scale modification or adjustment of the equipment, and improves the versatility and utilization rate of the equipment;

[0045] 6、The operation screen provides an intuitive and convenient man-machine interface for the operator, which facilitates the operator to monitor the equipment running state in real time, view various operation parameters, and make necessary parameter adjustment and manual intervention, reduces the operation difficulty and the requirement for professional skills of the operator, and makes the operation of the equipment more humanized. BRIEF DESCRIPTION OF DRAWINGS

[0046] Figure 1 is a control structure schematic diagram of wire uncoiling and warehousing. DETAILED DESCRIPTION

[0047] The application will be described in detail below with reference to the accompanying drawings, but it should be pointed out that the implementation of the application is not limited to the following embodiments.

[0048] The following examples are implemented on the premise of the technical solutions of the application, and detailed embodiments and specific operation processes are given, but the protection scope of the application is not limited to the following examples. The methods used in the following examples are all conventional methods unless otherwise specified.

[0049] Example 1

[0050] A control system for wire coil unloading into a warehouse includes a 1# unloading trolley 1, a 2# unloading trolley 2, distance detection sensors LL01 and LL02, occupancy sensors LS11-LS14 and LS21-LS24, and measurement sensors LS10 and LS20. The distance detection sensors LL01 and LL02 are respectively installed at the end of the unloading trolley pit, as shown in Figure 1 ; the measurement sensors LS10 and LS20 are respectively installed at the entrance position of the unloading table, as shown in Figure 1 , for measuring the end position and length of the wire coil; the occupancy sensors LS11-LS14 and LS21-LS24 are uniformly arranged on the unloading table according to the average number of coil lengths, as shown in Figure 1 , for positioning the number of coils on the unloading table; the detection sensors, measurement sensors, and occupancy sensors all use photoelectric reflection detection sensors. In the case of no coil, the occupancy sensors LS11-LS14 and LS21-LS24 all have no signal, and the PLC system controls the unloading trolley to unload the end of the first coil at the A 11 position, while storing the coil length L1 in the system, and sequentially unloading the second, third, and fourth coils; if three coils are unloaded, the crane lifts away the last two coils, and the occupancy sensor LS11 still retains a wire coil, and the PLC system controls the unloading trolley to automatically unload the end of the wire coil at the A 12 position. Through the detection, calculation, and data storage of the PLC system, the arrival of the wire coil can be automatically recognized, thereby triggering the unloading operation at the corresponding position; the PLC system includes a CPU module, an HMI human-computer interaction screen, and a digital quantity input module, the CPU module and the digital quantity input module are connected through ports, the CPU module and the HMI human-computer interaction screen are connected through ports, and the distance detection sensors LL01 and LL02, the photoelectric reflection detection sensors LS10-LS14, and the photoelectric reflection detection sensors LS20-LS24 are respectively connected with the digital quantity input module through ports.

[0051] A control method for wire coil unloading into a warehouse, specifically comprising:

[0052] Step S1, system initialization and preparation, including:

[0053] The unloading trolley is in the initial position;

[0054] The detection sensor, the measurement sensor, the occupancy sensor, and the HMI man-machine interaction screen are in the standby state, and the standby state includes:

[0055] The distance detection sensors LL01 and LL02, the measurement sensors LS10 and LS20, and the occupancy sensors LS11-LS14 and LS21-LS24 have no obstructions in the detection range.

[0056] The initial roll spacing of the packaged wire roll is set to (-50mm-0) on the HMI man-machine interaction screen, and the initial roll spacing of the non-packaged wire roll is set to (0-50mm).

[0057] Step S2, unloading control:

[0058] The unloading trolley advances on the track, and when the measurement distance of the first wire roll from the distance detection sensor LL01 or the distance detection sensor LL02 reaches A 11 , the unloading trolley stops; the value of a is 13000mm;

[0059] The calculation formula of the head position A 11 of the first wire roll is as follows:

[0060] A 11 =S 11 +a;

[0061] L1=S 21 -S 11 ①;

[0062] In formula ①, a represents the distance from the head position A 11 of the first wire roll to the distance sensor, and the value is 13000mm;

[0063] A 11 ==4543mm+13000mm=17543mm;

[0064] L1=6263-4543=1720mm;

[0065] The unloading trolley advances on the track, and when the measurement distance of the second wire roll from the distance detection sensor LL01 or the distance detection sensor LL02 reaches A 12 , the unloading trolley stops, and the unloading positioning of the second wire roll is completed;

[0066] The calculation formula of the head position A 12 of the second wire roll is as follows:

[0067] A 12 =S 12+ a-L1-m;

[0068] L2=S 22 -S 12 ②;

[0069] In formula 2, m represents the winding pitch, and is 20 mm;

[0070] A 12 = 4452 + 13000 - 1720 - 20 = 15712 mm;

[0071] L2=S 22 -S 12 = 6202 - 4452 = 1750 mm;

[0072] When the measuring distance of the unloading trolley on the track to the third winding wire coil distance detection sensor LL01 or distance detection sensor LL02 reaches A 13 , the unloading trolley stops, and the unloading positioning of the third winding wire coil is completed;

[0073] The calculation formula of the head position A 13 of the third winding wire coil is as follows:

[0074] A 13 =S 13 +a-L1-L2-2m;

[0075] L3=S 23 -S 13 ③;

[0076] In formula 3,

[0077] A 13 = 4500 + 13000 - 1720 - 1750 - 2*20 = 13990 mm;

[0078] L3= 6265 - 4500 = 1765 mm;

[0079] When the measuring distance of the unloading trolley on the track to the fourth winding wire coil distance detection sensor LL01 or distance detection sensor LL02 reaches A 14 , the unloading trolley stops, and the unloading positioning of the fourth winding wire coil is completed;

[0080] The calculation formula of the head position A 14 of the fourth winding wire coil is as follows:

[0081] A 14 =S 14 +a-L1-L2-L3-3m④;

[0082] In formula 4,

[0083] A 14 =4552+13000-1720-1750-1765-3x20=12257mm.

[0084] Step S3, roll spacing adjustment and mode switching, as follows:

[0085] The operator manually adjusts the wire roll spacing m parameter through the HMI human-computer interaction screen, for adapting to wire rolls of different length specifications; the initial value sets m to 20 mm, and the actual spacing of the wire rolls on the unloading table is observed; if the actual spacing is greater than 20 mm, the value of m is reduced; if the wire rolls on the unloading table appear to be loaded, the car does not fall after reaching the position, and the like, the value of m is increased.

[0086] S4, unloading completion and resetting, including:

[0087] After unloading is completed, operation data is recorded, including the unloading quantity, roll spacing, and operation time;

[0088] The operator issues a reset instruction through the HMI human-computer interaction screen, and the unloading car returns to the initial position, preparing for the next round of unloading operation.

[0089] Example 2

[0090] In this embodiment, a control method for wire unloading and warehousing is the same as that in Example 1, and a control process for wire unloading and warehousing is added on the basis thereof.

[0091] A control process for wire unloading and warehousing based on HMI human-computer interaction screen operation, steps as follows:

[0092] Step 1, preparation work:

[0093] The operator first performs preparation work to ensure normal operation of the equipment:

[0094] a) Equipment start: the operator starts the equipment to ensure that the unloading car is in the initial position;

[0095] b) Check the sensor and system state: check the installed detection sensor, measurement sensor, occupancy sensor, PLC system, and HMI human-computer interaction screen to ensure that their working states are normal and there are no abnormal signals or faults.

[0096] Step 2, unloading parameter setting: according to different wire roll product specifications, the operator needs to set corresponding unloading parameters to ensure the accuracy of the unloading process:

[0097] a) The operator selects the "with packaging" or "without packaging" mode according to the packaging condition of the product to be unloaded; the initial set roll spacing is: -50 mm for the "with packaging" mode and 50 mm for the "without packaging" mode.

[0098] b) Click the "unwinding" button to perform the first unwinding operation, and remove the first coil; then click the "unwinding" button again to remove the second coil; observe whether the distance between the two coils is within 50mm, if not, manually hang the coil back on the PF chain and adjust the coil spacing before re-unwinding operation.

[0099] c) Click the "unwinding" button to perform the third coil unwinding operation, and observe whether the third coil will block the photoelectric opposite of the fourth coil; if it blocks, it means that the length specification of the coil can only be unwound three coils at a time, and the operator should select the "continuous unwinding of three coils" mode; if it does not block, the length specification of the coil can be unwound four coils at a time, and the operator should select the "continuous unwinding of four coils" mode.

[0100] Step 3, Unwinding: After setting the unwinding parameters (including "whether there is packaging" selection, "coil spacing" setting, "unwinding quantity" setting, "1# car / 2# car" use selection), the operator can start the unwinding mode to make the unwinding trolley automatically execute the unwinding operation:

[0101] Start automatic unwinding mode: According to the site requirements, two automatic modes are configured, which can be switched through the "automatic / semi-automatic" selection switch:

[0102] a) Semi-automatic unwinding mode

[0103] When each coil reaches above the unwinding trolley, a ready signal is sent, and the "unwinding" button is clicked. The trolley automatically rises to lift the coil, advances to place the coil, and then descends to return to the initial position. The next time the coil reaches above the unwinding trolley, the "unwinding" button needs to be clicked again. Each coil needs to be manually triggered once.

[0104] b) Full-automatic unwinding mode

[0105] After clicking the "unwinding" button, the unwinding trolley will automatically determine the number of unwinding coils according to the "unwinding three coils / unwinding" set in step 2, and then enter the waiting state. After the crane has lifted all the coils on the unwinding table, click the "unwinding" button again, and the unwinding trolley will unwind another group of coils. Each group needs to be manually triggered once.

[0106] Manual intervention: During the automatic unwinding process, the operator needs to pay attention to the following situations, and manual intervention is required if an abnormality occurs:

[0107] a) The automatic uncoiling trolley does not stop at the designated position, and it is suspected that there is foreign matter blocking the photoelectric sensor elements on the uncoiling table, causing detection abnormalities and affecting the calculation of the PLC system. If it is the first coil, the line coil can be manually returned to the initial position, and the photoelectric sensor elements can be checked. If it is the middle coil, the current group of coils can be manually unloaded, and the inspection can be performed after the crane is lifted away.

[0108] b) Before clicking the "uncoiling" button each time, the operator needs to confirm that the current line coil to be unloaded is a qualified product, ensuring that there are no abnormal situations such as scattered coils, small coils, or scales. If abnormalities are found, the "manual" button should be clicked immediately to pause the automatic uncoiling operation, and the unqualified product should be manually placed out of the uncoiling station and processed in the next area.

[0109] 4. Regular equipment maintenance and inspection: In order to ensure the long-term stable operation of the system, all elements on site need to be regularly maintained and inspected:

[0110] Element inspection: Equipment maintenance personnel should regularly inspect key elements, including distance detection sensors, photoelectric sensor detection sensors, PLC systems, and HMI human-machine interaction screens, to ensure their normal operation and no damage or wear and tear.

[0111] Cleaning and maintenance: Regularly clean the dust on the surface of the equipment, and wipe the sensor lens and other components to ensure the accuracy of the detection and the overall operation of the equipment.

[0112] Maintenance records: Maintenance personnel should record each inspection and maintenance work in detail to form a device maintenance file, so as to track the running status and maintenance history of the equipment, and timely discover and handle potential problems.

[0113] The application can accurately detect the position, spacing and length of the wire coil by the distance detection sensor and the photoelectric opposite detection sensor, so as to realize accurate positioning and measurement of the wire coil, avoid errors caused by manual visual judgment, and improve the accuracy of the uncoiling operation; according to the measured distance value, the uncoiling position of each wire coil can be accurately determined by using the calculation formula, so as to ensure that the wire coils maintain appropriate spacing and prevent the end of the coil from being scratched due to too small spacing, thereby improving the stability of product quality; with the help of detection and PLC system, the end of the wire coil can be effectively prevented from being scratched during uncoiling and hoisting, so as to ensure the appearance quality and performance of the wire, reduce the risk of quality disputes caused by surface damage, help maintain the reputation and customer satisfaction of the enterprise; due to the significant improvement in the accuracy and consistency of the uncoiling operation, the quality of each wire coil is more stable and reliable, the quality fluctuation caused by unstable operation is reduced, and the enterprise can establish a good brand image in market competition; the system has a coil spacing adjustment function, the operator can set the coil spacing through the operation screen according to different specifications of the wire coil, reduces the direct contact of the operator with the equipment on site, saves time and workload for adjusting the coil spacing, further improves the production efficiency, and reduces the risk of time waste and production delay caused by improper manual adjustment; in the past, the operator needed to concentrate for a long time to visually judge and operate the uncoiling trolley manually, and the labor intensity was large; in the application, the operator only needs to perform simple operations for necessary monitoring and parameter setting, which greatly reduces the labor intensity; the direct contact and frequent operation of the operator with the equipment are reduced, the risk of work accidents caused by manual operation errors is reduced, a safer working environment is provided for the production site, and the requirements of modern enterprise safety production are met; for different specifications of the wire coil, the operator only needs to set the related parameters through the operation screen, and the PLC system can adjust the uncoiling mode and the coil spacing, so that the device has good adaptability to various specifications of products, without the need for large-scale modification or adjustment of the device, and the versatility and utilization rate of the device are improved; the operation screen provides an intuitive and convenient man-machine interface for the operator, which facilitates the operator to monitor the running state of the device, check the operation parameters, and make necessary parameter adjustment and manual intervention, reduces the operation difficulty and the requirement for professional skills of the operator, and makes the operation of the device more humanized.

Claims

1. A control method for unwinding and storing wire rod, characterized in that, Based on the coordinated operation of distance detection sensors and measurement sensors, the unwinding and warehousing of wire coils is completed through a PLC system, specifically including: S1. Equipment initialization check; S2, Unwinding Control: The unloading trolley lifts the coil and moves it forward on the track. The head of the first coil is at position A. 11 The calculation formula is as follows: A 11 =S 11 +a①; L1=S 21 -S 11 ②; In formulas ① and ②, S 11 This indicates the distance sensor reading when the head of the first coil of wire reaches the measuring sensor; 'a' indicates the head position A of the first coil of wire. 11 The distance to the ranging sensor, where 'a' is greater than 5 times the maximum coil length; S 21 L1 represents the distance sensor reading when the tail of the first coil reaches the measuring sensor; L2 represents the length of the first coil. The head position A of the second roll of thread 12 The calculation formula is as follows: TO 12 =S 12 +a-L1-m③; L2=S 22 -S 12 4; In formulas ③ and ④, S 12 This indicates the distance detected by the distance sensor when the head of the second coil reaches the measuring sensor; m represents the coil spacing; S 22 L2 represents the distance sensor reading when the end of the second coil reaches the measuring sensor; L2 is the length of the second coil. The beginning position A of the nth roll of thread 1n The calculation formula is as follows: TO 1n =S 1n +a-L1-L 2-…- L n-1 -m(n-1)⑤; L n =S 2n -S 1n ⑥; In formulas ⑤ and ⑥, S 1n This represents the distance detection value of the distance sensor when the head of the nth coil reaches the measuring sensor; S 2n This indicates the distance sensor reading when the end of the second coil reaches the measuring sensor; L n-1 This represents the length of the (n-1)th roll of thread; The value of n is determined by the length of the crane's magnetic weight and the multiple of the coil length. When the length of the crane's magnetic weight is 3 times the length of the coil, n equals 3; when the length of the crane's magnetic weight is 4 times the length of the coil, n equals 4.

2. The control method for unwinding and storing wire rod according to claim 1, characterized in that, In S1, the device initialization check includes: The unloading trolley is in its initial position; The distance detection sensor displays a value that matches the actual value. There are no obstructions within the detection range of the sensor. If the sensor is obstructed, the corresponding indicator light will change.

3. The control method for unwinding and storing wire rod according to claim 1, characterized in that, It also includes unwinding operations, as detailed below: Select the unloading trolley; The corresponding unloading trolleys continuously unload coils. Once the unloading platform is full and the crane lifts the coils away, the next round of automatic unloading begins.

4. The control method for unwinding and storing wire rod according to claim 1, characterized in that, The distance detection sensor is used to measure the traveling position of the unwinding trolley; the measurement sensor is used to measure the position of the wire roll on the unwinding trolley.

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