Water meter screwing control method and equipment

Abstract

The invention relates to a water meter screwing control method and equipment, and the method comprises the steps: carrying out the real-time detection of the screwing speed and torque in the screwing process of a water meter, adopting different processing flows for the situation that the screwing of the water meter fails due to the screw loosening and clamping in the screwing process, recognizing the screw loosening and clamping situations according to the real-time torque and rotating speed of a servo, and carrying out the real-time detection of the screwing speed and torque of the water meter. If the servo feedback torque value is within the set target torque interval, it is judged that screwing is qualified. According to the water meter screwing control method, automatic screwing production of the water meter cover can be achieved in the actual production process, the production efficiency is improved, the yield of water meters in the production process is greatly improved, and the labor cost is reduced.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of automation, and particularly relates to a water meter screwing control method and device. BACKGROUND

[0002] The automation process of water meter production significantly improves the competitiveness of manufacturing industry by improving production efficiency, ensuring product quality, reducing cost and enhancing safety, and the control system plays a core role in it, ensuring the efficient and stable operation of the automated production line through precise control, real-time monitoring, data analysis and system stability, thereby realizing the overall optimization of the production process. The automatic screwing between the water meter cover and the water meter shell is a crucial link in the automatic production process of the water meter, which greatly determines the stability of the water meter quality, and the automatic production process greatly ensures the product quality, so a practical and effective water meter screwing control method is very necessary in the water meter production process in the current industrial production process.

[0003] The current water meter screwing is still carried out by manual combination with semi-automatic equipment for screwing control of the water meter cover and the water meter shell. This screwing method has the disadvantages of low efficiency, inconsistent quality, high labor intensity, low operation safety and high cost. In addition, due to the changes in experience, physical strength or attention of workers, it is difficult to ensure the precision and consistency of screwing, resulting in unstable product quality. Automation production solves the problem of production efficiency to a great extent. With the help of automated equipment and reliable water meter screwing control method, automatic screwing can accurately control the torque and screwing force, ensuring the quality consistency of each water meter and eliminating manual errors. Especially in large-scale production process, automatic screwing control greatly reduces the labor cost and realizes effective support for complex and high-precision operations.

[0004] However, the automatic water meter screwing control is affected by multiple factors, among which the screwing between the cover and the water meter shell is affected by the material, specification and environment of the water meter, and then the torque anomaly and water meter slip occur. In view of the above problems, a good control algorithm needs to have a fault-tolerant mechanism to judge and handle these anomalies according to the torque to avoid damaging the water meter and the production automation equipment. In addition, it is required to be completed within a limited time to ensure real-time control of the control algorithm, which puts forward higher requirements for the algorithm. SUMMARY

[0005] In view of the above technical problems, the application provides a water meter screwing control method, which determines various states in automatic screwing between a water meter cover and a water meter shell through real-time collected torque, and gives corresponding solutions if sticking, slipping and other situations occur during water meter screwing. For example, high-speed reverse rotation is performed after sticking to solve screwing failure caused by sticking. For the slipping situation, a low-speed screwing scheme is adopted to reduce the rotation speed, and the low-speed screwing times are determined to improve the screwing qualified rate. The application can greatly improve the production efficiency in the actual production process, greatly improve the yield of water meters in the production process, and reduce the labor cost.

[0006] In order to achieve the above technical purpose, the application adopts the following technical scheme:

[0007] A water meter screwing control method, comprising the following steps,

[0008] Step 1: initialize variables, set the speed of the servo in different stages and the target torque threshold value;

[0009] Step 2: wait for the water meter tray to reach the work station, and determine whether there is a water meter in the tray through the photoelectric sensor; if there is a water meter, execute step 3;

[0010] Step 3: control the screwing mechanism to press down, so that the screwing head is attached to the water meter cover;

[0011] Step 4: control the servo motor to rotate at a speed Low-speed pre-rotation, real-time collection of the current torque value T;

[0012] Step 5: determine whether the current torque value T is greater than the historical sticking torque ; if T> , then:

[0013] control the servo motor to rotate at a speed High-speed reverse rotation, reset under the condition of sticking, and the number of high-speed reverse rotations is 1;

[0014] if T≤ , execute step 6;

[0015] Step 6: control the servo motor to rotate at a speed Execute fast screwing;

[0016] Step 7: determine whether the current torque value T is greater than the first-stage torque threshold value ; if T< , determine whether T is greater than the last sampling torque value , if T≤ , determine that the water meter is unqualified, reset the low-speed screwing counter, disable the servo motor and reset the air cylinder, and return to step 3;

[0017] If T > T1, execute step 8;

[0018] Step 8: control the servo motor to rotate at a speed of V2 for a preset time length. Execute the second stage of screwing; if the current torque value T is greater than the second stage torque threshold value T2, keep the screwing state for a preset time length, and return to step 3.

[0019] Beneficial effects: The water meter screwing control method of the present application determines the current screwing state according to the real-time collected torque. Specifically, if the current torque value T is greater than the historical torque value T0, it is determined that the water meter is stuck, the servo motor is set to high-speed reverse rotation, the problem of being unable to continue screwing caused by sticking is solved, and the water meter shell and the cover are restored to the initial state of screwing. If the current torque value T is less than or equal to the last time sampling torque value T1, it is determined that the water meter is slipping, the low-speed screwing counter is reset, the servo motor is disabled, and the cylinder is reset, so that the water meter cover and the water meter body with problems can be timely taken offline, defective products can be timely found, screwing failure caused by defective products can be excluded, and the success rate of screwing and the production efficiency can be effectively improved.

[0020]

[0021] The water meter screwing control method of the present application realizes intelligent control in the production process of the water meter, can greatly improve the production efficiency compared with the existing manual production process, can improve the yield of the water meter in the production process, and can reduce the labor cost.

[0022] In an optional embodiment, in step 2, if the tray has no water meter, the tray is released and the current screwing process is terminated.

[0023] In an optional embodiment, in step 5, if T > T1, the upper limit is set, it is determined that the water meter is unqualified, the servo motor is disabled, and the cylinder is reset.

[0024] Beneficial effects: If the number of high-speed reverse rotations exceeds the set upper limit, it is indicated that the water meter body or the water meter cover may be unqualified, so that the number of screwing exceeds the set value. It is determined that the screwing result of the water meter fails, the servo motor is disabled, and the cylinder is reset.

[0025] In an optional embodiment, in step 7, if T > T1, step 72 is executed. Step 72: control the servo motor to rotate at a speed of V1 for a preset time length.

[0026] ​​​​​​​​​​​

[0027] If the low-speed screwing time t low > timeout threshold t timeout , step 71 is performed.

[0028] In an alternative embodiment, in step 72, if t low ≤ t timeout , step 73 is performed:

[0029] Step 73: determine whether the current torque value T > the first-stage torque threshold ; if T ≤ , step 71 is performed.

[0030] Beneficial effect: setting the first-stage torque determines the current screwing condition, and timely observing whether the screwing is slipping, taking low-speed screwing, reducing the rotation speed, and reducing the screwing failure caused by slipping.

[0031] In an alternative embodiment, in step 73, if the current torque value T > the first-stage torque threshold , step 731 is performed: determining the number of low-speed screwing times > setting an upper limit; if it exceeds, step 71 is performed; otherwise, step 8 is performed.

[0032] Beneficial effect: realizing real-time torque judgment in the water meter screwing process, when the slipping condition still exists and exceeds the set number of times, the water meter is timely taken offline, and if the low-speed screwing reaches the set torque, the water meter screwing is completed.

[0033] The application further discloses a computing device comprising at least one processor and a memory;

[0034] The memory stores computer execution instructions;

[0035] At least one processor executes the computer execution instructions stored in the memory, so that the at least one processor executes the water meter screwing control method. BRIEF DESCRIPTION OF DRAWINGS

[0036] Figure 1 is a torque and rotation speed monitoring diagram applied to the water meter screwing process of the application;

[0037] Figure 2 is an algorithm flowchart of the application. DETAILED DESCRIPTION

[0038] The specific embodiments of the application are further described below in combination with the drawings.

[0039] The present case takes actual production as an example, takes PLC as a controller, servo motor air cylinder and the like as output devices, designs a pre-experiment, and designs a torque is 30 N·m, first stage torque is 50 N·m, second screwing torque is 80 N·m, second design low speed pre-rotation speed is 500 rmp, high speed anti-rotation speed is -800 rmp, fast tightening speed is 800 rmp, low speed screwing speed is 300 rmp, final tightening speed is 200 rmp, high speed anti-rotation times is set to 5, low speed screwing times is set to 3.

[0040] The present application in the actual water meter cover and water meter shell screwing process as follows:

[0041] Step 1: first, the state variable initialization, water meter tray to arrive.

[0042] Step 2: water meter tray to reach the station, through the photoelectric sensor to collect variables to determine whether there is a water meter in the water meter tray, if there is a water meter, step 3 is executed;

[0043] Step 3: execute the screwing mechanism down command, that is, the water meter screwing mechanism and water meter cover fit;

[0044] Step 4: collect the current torque value T, control the servo motor with speed low speed pre-rotation, speed is 500 rmp;

[0045] Step 5: determine whether the current torque value T is greater than the historical jam torque , is 30 N·m; if T≤ , step 6 is executed, if the jam occurs, step 6 is executed, otherwise step 7 is executed;

[0046] Step 6: servo motor high speed anti-rotation, anti-rotation speed is -800 rmp, then the number of anti-rotation is added one, if the number of anti-rotation is greater than 5 times, it represents that the water meter is unqualified, the servo motor is disabled, and the cylinder returns to the original point task is executed;

[0047] Step 7: reset the anti-rotation counter, control the servo motor with speed execute fast tightening; is 800 rmp;

[0048] Step 8: determine whether the current torque value T is greater than the first stage torque threshold , is 50 N·m, if the current current torque value T is greater than 50 N·m, step 9 is executed, otherwise step 10 is executed;

[0049] Step 9: control servo motor to rotate at speed perform second stage rotation, 800rmp, if current torque value T> second stage torque threshold , 65N.m, then determine that the water meter is qualified, wait for rotation holding time 3s, perform servo motor disable, cylinder back to origin, perform step 3;

[0050] Step 10: further determine whether T is greater than historical torque reference value ; if T≤ , perform step 11, if greater than historical torque, perform step 12;

[0051] Step 11: reset low speed rotation counter, determine that the water meter is unqualified, disable servo motor and reset cylinder, return to step 3;

[0052] Step 12: control servo motor to rotate at speed low speed rotation, 500rmp, low speed rotation times add 1;

[0053] Step 13: determine whether current low speed rotation time is greater than 5s, if low speed rotation time is greater than 15s, perform step 11, if less than 5s, perform step 14;

[0054] Step 14: determine whether current torque is greater than first stage torque, if less than first stage torque 50 N.m, perform step 11, if greater than first stage torque, perform step 15;

[0055] Step 15: determine whether low speed rotation times exceed 3 times, if exceed specified times, perform step 11, otherwise perform step 9.

[0056] The above steps are specific application of the present application in actual water meter rotation process. In order to the effectiveness of the present application, taking the cover rotation process history record of 19th day of a month as an example. Figure 1 contains current PLC control process step number, real-time torque value and rotation speed of rotation process. From the figure, it can be seen that the rotation process starts from 1.7s, starts to rotate at 500rmp, in this stage, the real-time torque starts to rise, after 5.8s, the rotation speed continues to rotate at 800rmp, there is no jamming in the rotation process, until the torque reaches 80N.m, meets the set requirement. After 10s, the rotation is finished, waits for rotation holding time 3s, maintains torque 65N.m, the rotation process is finished.

[0057] Part of the steps in the embodiments of the present application can be realized by software, and the corresponding software program can be stored in a readable storage medium, such as an optical disc or a hard disk.

[0058] The above merely describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A method for controlling the turning of a water meter, characterized in that, Includes the following steps, Step 1: Initialize variables and set the speed and target torque thresholds for different stages of the servo operation; Step 2: Wait for the water meter tray to arrive at the workstation, and use a photoelectric sensor to determine whether there is a water meter in the tray; if there is a water meter, proceed to step 3; Step 3: Control the screwing mechanism to press down, so that the screwing head fits against the water meter cover; Step 4: Control the servo at speed Low-speed pre-spinning, and real-time acquisition of the current torque value T; Step 5: Determine if the current torque value T is greater than the historical jamming torque. If T> ,but: Control the servo motor at speed High-speed reversal enables reset in case of a stuck situation; number of high-speed reversals. Add 1; If T≤ Proceed to step 6; Step 6: Control the servo motor at a speed Perform a rapid tightening; Step 7: Determine if the current torque value T is greater than the first stage torque threshold. If T < Then determine whether T is greater than the sampled torque value at the previous moment. If T≤ The water meter was deemed unqualified. If T > Proceed to step 8; Step 8: Control the servo motor at a speed Perform the second stage of tightening; If the current torque value T is greater than the second-stage torque threshold If the screw is held in the screwing position for a preset time, return to step 3.

2. The water meter turning control method according to claim 1, characterized in that, In step 2, if the pallet does not have a water meter, the pallet is released and the current turning process is terminated.

3. The water meter turning control method according to claim 1, characterized in that, In step 5, like Set an upper limit, determine that the water meter is unqualified, disable the servo motor and reset the cylinder.

4. The water meter turning control method according to claim 1, characterized in that, In step 7, if T> Then proceed to step 72: Step 72: Control the servo motor at a speed Slow-speed turning, number of low-speed turnings Add 1; If the low-speed twisting time t low Timeout threshold t timeout Proceed to step 71.

5. The water meter turning control method according to claim 4, characterized in that, In step 72, if t low ≤t timeout Then proceed to step 73: Step 73: Determine if the current torque value T > the first stage torque threshold. If T ≤ Proceed to step 71.

6. The water meter turning control method according to claim 5, characterized in that, In step 73, if the current torque value T > the first stage torque threshold Then proceed to step 731: Step 731: Determine the number of low-speed turning cycles Has the set limit been exceeded? If the error exceeds the limit, proceed to step 71; Otherwise, proceed to step 8.

7. A computing device, characterized in that, Includes at least one processor and memory; The memory stores computer-executed instructions; At least one of the processors executes computer execution instructions stored in the memory, causing at least one of the processors to perform the water meter turning control method as described in any one of claims 1-6.

Images