A control method for wire rod uncoiling into a warehouse

Abstract

The present application relates to the field of steel production, and more particularly to a control method for wire rod coil unloading and storage, comprising unloading control: the unloading trolley lifts the wire coil and advances on the track, calculates the head position A of the first wire coil 11 , calculates the head position A of the second wire coil 12 , and calculates the head position A of the nth wire coil 1n . The present application has the advantages that: through the distance detection sensor and the photoelectric opposite detection sensor, the key parameters of the position, spacing and length of the wire coil can be accurately detected, 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 unloading operation; according to the measured distance value, the unloading position of each wire coil can be accurately determined by using the calculation formula, the appropriate spacing between the wire coils is ensured, the problem of scratch on the end of the coil caused by too small spacing is prevented, and the stability of product quality is improved.

Description

Technical Field

[0001] This invention relates to the field of steel production, and more particularly to a control method for uncoiling and storing wire rod. Background Technology

[0002] In the production process of wire rod products, the unwinding and warehousing stage, as the final step, is crucial for ensuring production efficiency and maintaining product quality. Traditional wire rod factories generally use manually operated unwinding trolleys for this operation, which presents the following main problems:

[0003] 1. Insufficient operational precision

[0004] Some workshops use manually operated unwinding trolleys, relying entirely on workers to visually judge the spacing between wire coils and manually operate the movement and parking of the unwinding trolley; this operating method lacks precision and often results in the spacing between wire coils being set too small.

[0005] 2. The ends of the coil are easily damaged.

[0006] When the spacing between wire coils is too small, the ends of the coils are prone to scratches during subsequent hoisting, resulting in surface damage. This not only affects the appearance quality of the wire but may also have an adverse effect on its performance, leading to quality disputes.

[0007] 3. Frequent quality problems

[0008] Because operators cannot ensure that sufficient unwinding spacing is maintained in every unwinding operation, product quality is unstable and quality disputes occur frequently.

[0009] 4. Low efficiency and security

[0010] Manually operating the unloading trolley is inefficient, prone to errors, and increases the workload for workers. Furthermore, frequent manual operation poses certain safety hazards.

[0011] While some automated unloading devices exist in the existing technology, they suffer from insufficient functionality or low levels of intelligence.

[0012] The patent publication number CN215974183U discloses "a fully automatic uncoiling device for rolled steel wire", which fixes the wire coil through a clamping mechanism, improving work efficiency and safety, but lacks the function of precise control and adjustment of the wire coil spacing.

[0013] In conclusion, the traditional manual unwinding and warehousing method is difficult to meet the requirements of modern wire rod production for high efficiency, high quality, and high safety. Summary of the Invention

[0014] The purpose of this invention is to provide a control method for unwinding and storing wire, which solves the problems of insufficient accuracy due to reliance on manual operation, product damage caused by improper control of wire coil spacing, low operating efficiency, and poor safety in the prior art.

[0015] To achieve the above objectives, the present invention provides the following technical solution:

[0016] A control method for unwinding and storing wire coils, based on the coordinated operation of distance detection sensors and measurement sensors, uses a PLC system to complete the unwinding and storage of wire coils, specifically including:

[0017] S1. Equipment initialization check;

[0018] S2, Unwinding Control:

[0019] 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:

[0020] A 11 =S 11 +a①;

[0021] L1=S 21 -S 11 ②;

[0022] 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.

[0023] The head position A of the second roll of thread 12 The calculation formula 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 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.

[0027] The beginning position A of the nth roll of thread 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 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;

[0031] 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.

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

[0033] The unloading trolley is in its initial position;

[0034] 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.

[0035] The unwinding procedure is as follows:

[0036] Select the unloading trolley;

[0037] 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.

[0038] Distance detection sensors are used to measure the traveling position of the unwinding trolley; measurement sensors are used to measure the position of the wire roll on the unwinding trolley.

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

[0040] 1. By using distance detection sensors and photoelectric beam detection sensors, the key parameters of the wire roll's position, spacing, and length can be accurately detected, thereby achieving precise positioning and measurement of the wire roll, avoiding errors caused by manual visual judgment, and improving the accuracy of unwinding operations; based on the measured distance values, the unwinding position of each wire roll can be accurately determined using calculation formulas, ensuring that the wire rolls maintain a suitable spacing, preventing scratches on the roll ends due to insufficient spacing, and improving the stability of product quality;

[0041] 2. With the help of detection and PLC systems, scratches on the ends of wire coils during unwinding and hoisting are effectively avoided, ensuring the appearance quality and performance of the wire, reducing the risk of quality disputes caused by surface damage, and helping to maintain the company's reputation and customer satisfaction; due to the significantly improved accuracy and consistency of unwinding operations, the quality of each coil of wire is more stable and reliable, reducing quality fluctuations caused by operational instability.

[0042] 3. The system has a roll spacing adjustment function. Operators can set the roll spacing through the operation screen according to different specifications of wire rolls, reducing direct manual contact with the equipment on site, saving time and workload for adjusting the roll spacing, further improving production efficiency, and also reducing the risk of time waste and production delays caused by improper manual adjustment.

[0043] 4. In the past, the manual control of the unloading trolley required operators to concentrate for long periods of time on visual judgment and operation, resulting in high labor intensity. In this invention, operators only need to perform simple operations such as necessary monitoring and parameter setting, which greatly reduces labor intensity. It also reduces direct contact between the operator and the equipment and frequent operation, thereby reducing the risk of work-related accidents caused by human error and providing a safer working environment for the production site, which meets the requirements of modern enterprise safety production.

[0044] 5. For wire coils of different specifications, operators only need to set relevant parameters through the operation screen, and the PLC system can adjust the unwinding method and coil spacing, achieving good adaptability to various specifications of products. There is no need to carry out large-scale modification or adjustment of the equipment, which improves the versatility and utilization of the equipment.

[0045] 6. The control panel provides operators with an intuitive and convenient human-machine interface, making it easy for operators to monitor the equipment's operating status in real time, view various operating parameters, and make necessary parameter adjustments and manual interventions. This reduces the difficulty of operation and the requirements for operators' professional skills, making the operation of the equipment more user-friendly. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the control structure for unwinding wire into the warehouse. Detailed Implementation

[0047] The present invention will now be described in detail with reference to the accompanying drawings, but it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0048] The following embodiments are implemented based on the technical solution of the present invention, providing detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments. Unless otherwise specified, the methods used in the following embodiments are conventional methods.

[0049] Example 1

[0050] A control system for unwinding and storing wire rod includes a No. 1 unwinding trolley 1, a No. 2 unwinding trolley 2, distance detection sensors LL01 and LL02, position sensors LS11~LS14 and LS21~LS24, and measurement sensors LS10 and LS20. The distance detection sensors LL01 and LL02 are respectively installed at the ends of the unwinding trolley pits. Figure 1 Measurement sensors LS10 and LS20 are installed at the entrance of the unloading table, see [link / details]. Figure 1 Used to measure the position of the end of the wire coil and the length of the wire coil; the occupant sensors LS11~LS14 and LS21~LS24 are evenly arranged on the unwinding table according to the average length of the coil, see Figure 1 This is used to locate the number of rolls on the unloading table; the detection sensor, measurement sensor, and occupancy sensor all adopt photoelectric through-beam detection sensors. When there is no roll, occupancy sensors LS11~LS14 and LS21~LS24 have no signal, and the PLC system controls the unloading trolley to unload the end of the first roll onto A. 11 The system stores the location and length of roll L1 in the system, and unloads rolls two, three, and four in sequence. If three rolls are unloaded, the crane removes the last two rolls, leaving one roll at the occupancy sensor LS11. The PLC system controls the unloading trolley to automatically unload the end of the roll at point A. 12 Position. Through the detection, calculation, and data storage of the PLC system, the positioning of the wire roll can be automatically identified, thereby triggering the unwinding operation at the corresponding position. The PLC system includes a CPU module, an HMI human-machine interface, and a digital input module. The CPU module and the digital input module are connected through ports, and the CPU module and the HMI human-machine interface are connected through ports. Distance detection sensors LL01, LL02, photoelectric beam detection sensors LS10~LS14, and photoelectric beam detection sensors LS20~LS24 are respectively connected to the digital input module through ports.

[0051] A control method for unwinding and storing wire rods, specifically including:

[0052] Step S1, System Initialization and Preparation, including:

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

[0054] The detection sensors, measurement sensors, occupancy sensors, and HMI (Human-Machine Interface) screen are in standby mode. Standby mode includes:

[0055] Distance detection sensors LL01 and LL02, measurement sensors LS10 and LS20, and occupancy sensors LS11~LS14 and LS21~LS24 are all within the detection range and there are no obstructions.

[0056] On the HMI human-machine interface screen, the initial roll spacing of packaged wire rolls is set to (-50mm~0), and the initial roll spacing of unpackaged wire rolls is set to (0~50mm).

[0057] Step S2, Unwinding Control:

[0058] The unloading trolley moves forward on the track, and the first coil of wire reaches distance A measured by either distance detection sensor LL01 or distance detection sensor LL02. 11 At that time, the unloading trolley stops; the value of 'a' is 13000 mm;

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

[0060] A 11 =S 11 +a;

[0061] L1=S 21 -S 11 ①;

[0062] In formula ①, 'a' represents the head position A of the first roll of yarn. 11 The distance to the ranging sensor is set to 13000mm;

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

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

[0065] The unloading trolley moves forward on the track, and the second coil of wire reaches distance A measured by either distance detection sensor LL01 or distance detection sensor LL02. 12 At this time, the unloading trolley stops, completing the unloading and positioning of the second coil of wire.

[0066] The head position A of the second roll of thread 12 The calculation formula 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 roll spacing, which is 20mm.

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

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

[0072] The unloading trolley moves forward on the track, and the distance measured by the distance detection sensor LL01 or LL02 of the third coil of wire reaches A. 13 At this time, the unloading trolley stops, completing the unloading and positioning of the third coil of wire.

[0073] Head position A of the third roll of wire 13 The calculation formula 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=13990mm;

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

[0079] The unloading trolley moves forward on the track, and the distance measured by the fourth coil of wire detection sensor LL01 or LL02 reaches A. 14 At this time, the unloading trolley stops, completing the unloading and positioning of the fourth coil of wire.

[0080] Head position A of the fourth roll of wire 14 The calculation formula is as follows:

[0081] A 14 =S 14 +a-L1-L2-L3-3m④;

[0082] In formula ④,

[0083] A 14 =4552+13000-1720-1750-1765-3×20=12257mm.

[0084] Step S3, Volume Spacing Adjustment and Mode Switching, details are as follows:

[0085] Operators manually adjust the wire coil spacing parameter m through the HMI human-machine interface to accommodate wire coils of different lengths and specifications. The initial value of m is set to 20mm. The actual spacing of the wire coils on the unloading table is observed. If the actual spacing is greater than 20mm, the value of m is decreased. If there are problems such as the wire coils being loaded on the unloading table or the trolley not falling after it is in position, the value of m is increased.

[0086] S4. Unwinding and resetting, including:

[0087] Record the operation data after unwinding, including the number of unwound rolls, roll spacing, and operation time.

[0088] The operator issues a reset command through the HMI (Human-Machine Interface) screen, and the unloading trolley returns to its initial position, ready for the next unloading operation.

[0089] Example 2

[0090] In this embodiment, a control method for unwinding wire into a warehouse is the same as in Embodiment 1, but with the addition of a control process for unwinding wire into a warehouse.

[0091] A control process for unwinding and storing wire coils, based on an HMI (Human Interface Device) screen, includes the following steps:

[0092] Step 1: Preparation

[0093] The operators first perform preparatory work to ensure the normal operation of the equipment:

[0094] a) Equipment startup: The operator starts the equipment and ensures that the unloading trolley is in the initial position;

[0095] b) Check sensor and system status: Inspect the installed detection sensors, measurement sensors, occupancy sensors, PLC system and HMI human-machine interface to ensure that they are working properly and there are no abnormal signals or faults.

[0096] Step 2, Unwinding Parameter Setting: Depending on the specifications of different wire coil products, operators need to set corresponding unwinding parameters to ensure the accuracy of the unwinding process.

[0097] a) The operator selects the "packaged" or "unpackaged" mode according to the packaging status of the roll product to be unloaded; the initial roll spacing is set as follows: -50mm when packaged, and 50mm when unpackaged.

[0098] b) Click the "Unwind" button to perform the first unwind operation and unwind the first roll; then click the "Unwind" button again to unwind the second roll; observe whether the distance between the two rolls is within 50mm. If it is not within 50mm, manually hang the wire roll back on the PF chain, adjust the roll spacing setting, and then perform the unwind operation again.

[0099] c) Click the "Unwind" button to unwind the third roll. Observe whether the position of the third roll will block the photoelectric beam of the fourth roll. If it blocks, it means that the length specification of the wire roll can only unwind three wire rolls at a time, and the operator should select the "Continuous Unwind Three Rolls" mode. If it does not block, the length specification of the wire roll can unwind four wire rolls at a time, and the operator should select the "Continuous Unwind Four Rolls" mode.

[0100] Step 3, Unwinding and Loading: After setting all unwinding parameters (including "Packaging Available", "Roll Spacing", "Unwinding Quantity", and "Car #1 / Car #2" selection), the operator can start the unwinding mode, allowing the unwinding trolley to automatically perform the unwinding operation.

[0101] Activate automatic roll unloading mode: Two automatic modes are configured according to site requirements, which can be switched using the "Automatic / Semi-automatic" selector switch:

[0102] a) Semi-automatic unloading mode

[0103] When each coil of wire reaches the top of the unloading trolley, a ready signal is emitted. Clicking the "Unload" button causes the trolley to automatically rise, lift the coil, move forward to place it, and then descend back to its initial position. The "Unload" button must be clicked again when the next coil reaches the top of the unloading trolley. Each coil requires manual triggering once.

[0104] b) Fully automatic unloading mode

[0105] After clicking the "Unload" button, the unloading trolley will automatically determine the number of rolls to unload based on the "Unload three rolls / unload" setting in step 2. Then it will enter a waiting state. After the crane has lifted all the rolls off the unloading platform, click the "Unload" button again, and the unloading trolley will unload another set of rolls. Each set needs to be manually triggered once.

[0106] Manual intervention is required during automatic roll unloading. Operators should pay attention to the following situations and intervene manually if any abnormalities occur:

[0107] a) The unloading trolley did not stop at the designated position during automatic unloading. It is suspected that there is a foreign object blocking the photoelectric sensor on the unloading table, causing abnormal detection and affecting the calculation of the PLC system. If it is the first roll, the roll can be manually returned to the initial position and the photoelectric sensor can be checked. If it is an intermediate roll, the roll in this group can be manually unloaded and checked after the crane is lifted away.

[0108] b) Before clicking the “Unload” button each time, the operator must confirm that all the wire coils to be unloaded are qualified products and ensure that there are no abnormalities such as loose coils, small coils or weights; if any abnormality is found, the operator should immediately click the “Manual” button to pause the automatic unloading operation, manually release the hook to release the unqualified products out of the unloading station, and move them to the next area for processing.

[0109] 4. Regular Equipment Maintenance and Inspection: To ensure the long-term stable operation of this system, all components on site must be regularly maintained and inspected.

[0110] Component Inspection: Equipment maintenance personnel should regularly inspect all key components, including distance detection sensors, photoelectric beam detection sensors, PLC systems, and HMI human-machine interface screens, to ensure that they are working properly and free from damage or wear.

[0111] Cleaning and maintenance: Regularly clean the dust off the equipment surface and wipe the sensor lens and other components to ensure detection accuracy and overall equipment operating condition.

[0112] Maintenance Records: Maintenance personnel should keep detailed records of each inspection and maintenance task to create equipment maintenance files, so as to track the equipment's operating status and maintenance history and promptly identify and address potential problems.

[0113] This invention utilizes distance detection sensors and photoelectric beam detection sensors to accurately detect key parameters such as the position, spacing, and length of wire coils. This enables precise positioning and measurement of the wire coils, avoiding errors caused by manual visual judgment and improving the accuracy of unwinding operations. Based on the measured distance values, a calculation formula can accurately determine the unwinding position of each wire coil, ensuring appropriate spacing between coils and preventing scratches at the coil ends due to insufficient spacing, thus improving product quality stability. With the help of detection and PLC systems, scratches at the wire coil ends during unwinding and hoisting are effectively avoided, ensuring the appearance quality and performance of the wire, reducing the risk of quality disputes caused by surface damage, and helping to maintain the company's reputation and customer satisfaction. The significantly improved accuracy and consistency of unwinding operations make the quality of each wire coil more stable and reliable, reducing quality fluctuations caused by operational instability, which is beneficial for the company to establish a good brand image in market competition. The system has a coil spacing adjustment function, allowing operators to set the coil spacing through the operation screen according to different specifications of wire coils, reducing direct manual contact with equipment on-site and saving time and workload in adjusting the coil spacing. This invention further improves production efficiency while reducing the risk of time waste and production delays caused by improper manual adjustments. Previously, relying on manual control of the unloading trolley required operators to concentrate for extended periods on visual judgment and operation, resulting in high labor intensity. In this invention, operators only need to perform necessary monitoring and parameter setting, greatly reducing labor intensity. It also reduces direct contact and frequent operation with the equipment, lowering the risk of workplace injuries due to human error and providing a safer working environment that meets the requirements of modern enterprise safety production. For different specifications of wire coils, operators only need to set relevant parameters through the operation screen, and the PLC system can adjust the unloading method and coil spacing, achieving good adaptability to various specifications of products without requiring large-scale modification or adjustment of the equipment, thus improving the equipment's versatility and utilization. The operation screen provides operators with an intuitive and convenient human-machine interface, allowing them to monitor the equipment's operating status in real time, view various operating parameters, and make necessary parameter adjustments and manual interventions, reducing the difficulty of operation and the professional skills required of operators, making the equipment operation more user-friendly.

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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