Windproof curtain automatic spring winding torsion machine and winding method thereof

Abstract

The invention provides an automatic wind-proof curtain spring winding torsion machine and a winding method thereof, and belongs to the technical field of torsion spring winding. The automatic wind-proof curtain spring winding torsion machine comprises a spring winding machine, a PLC control system, a driving device, a turn number encoder and a torsion sensor; the PLC control system is connected with the driving device, the turn number encoder and the torsion sensor through a communication bus, and data interaction and instruction issuing are achieved. The PLC control system is used as a control center, collected data such as the number of turns and torsion are received, the driving device is driven to operate accurately, meanwhile, motor pulse signals and output shaft torsion are collected in real time through the encoder and the torsion sensor, the data are transmitted back to the PLC to form closed-loop control, high-precision control over the number of turns and the torsion is achieved, and the control precision is improved. Error interference of manual and angle conversion is eliminated, the torsion spring winding quality is improved, the product performance consistency is guaranteed, the defective product rate is reduced, the production efficiency is greatly improved, the large-scale production rhythm is adapted, and the productivity bottleneck is broken through.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of torsion spring winding, in particular to an automatic spring winding torsion machine for windproof curtain and a winding method thereof. BACKGROUND

[0002] The torsion spring winding refers to a torsion spring manufacturing process completed by manual or simple equipment in the production process of windproof curtain, and its main feature is to rely on manual counting and manual operation or to be completed with the assistance of simple equipment.

[0003] (I) Application and process of prior art

[0004] In the current production of windproof curtain, the torsion spring winding relies on manual or simple equipment: manual winding relies on manual counting and manual operation; and some simple equipment counts the number of turns by manual.

[0005] (II) Problems and reasons of prior art

[0006] (1) Large error in the number of turns: manual winding is prone to overwinding or underwinding due to fatigue and distraction, and the simple equipment has a large conversion error in the number of turns due to mechanical vibration and the precision of the angle sensor, resulting in poor consistency in the number of turns of the torsion spring.

[0007] (2) Poor product quality: uneven manual operation and rough torsion control of the simple equipment make the torsion of the torsion spring unstable, affecting the performance of the windproof curtain; and the error in the number of turns also causes the product size and performance to be substandard.

[0008] (3) Low production capacity: manual winding has low efficiency, and the simple equipment has short effective production time due to frequent calibration and debugging, which is difficult to meet the demand of large-scale production. SUMMARY

[0009] Therefore, in order to solve the above problems in the prior art due to manual winding, the present application provides an automatic spring winding torsion machine for windproof curtain and a winding method thereof, which takes a PLC control system as a control center, receives and collects data such as the number of turns and torsion, and drives the driving device to operate accurately, while the encoder and the torsion sensor are used to collect the motor pulse signal and the output shaft torsion in real time, the data is returned to the PLC to form a closed-loop control, the number of turns and the torsion are controlled with high precision, the error interference of manual and angle conversion is eliminated, the quality of the torsion spring winding is improved, the performance consistency of the product is ensured, the defective product rate is reduced, and the production efficiency is greatly improved, which is suitable for the rhythm of large-scale production and breaks through the bottleneck of production capacity.

[0010] In order to achieve the above-mentioned purpose, the present application provides the following technical solutions:

[0011] In a first aspect, the present application provides an automatic spring winding torsion machine for windproof curtain, comprising:

[0012] a spring winding machine;

[0013] PLC control system;

[0014] A driving device mechanically connects the square shaft of the spring winding machine and drives the rotation of the square shaft to realize the winding of the torsion spring.

[0015] A number of turns encoder is arranged at the shaft end of the driving device and rotates synchronously with the motor, and is used to calculate the number of turns and transmit the collected rotation pulse signal of the driving device to the PLC control system.

[0016] A torsion sensor is arranged at the output shaft of the driving device, is connected in series between the driving device and the winding square shaft, and collects real-time torsion data and returns the data to the PLC control system.

[0017] The PLC control system is connected with the driving device, the number of turns encoder and the torsion sensor through a communication bus to realize data interaction and instruction issuing.

[0018] Preferably, the application further comprises:

[0019] A human-computer interaction screen is in bidirectional communication with the PLC control system, receives user input parameters and displays the running state of the equipment.

[0020] Preferably, the clamping and running mechanism of the tool clamp in the spring winding machine is that the square shaft of the workpiece to be processed is inserted into the square sleeve of the spring winding machine to complete mechanical positioning, after triggering the starting process, the PLC control system calls preset process parameters or receives user instructions in real time, the driving device drives the square shaft according to the planned trajectory to complete the winding of the torsion spring.

[0021] Preferably, a displacement sensor is arranged on the tool clamp to monitor the displacement deviation of the clamped square shaft.

[0022] Preferably, the tool clamp is linked with the spring winding machine through a pneumatic or electric mechanism to realize the rapid clamping of the product.

[0023] Preferably, the driving device is a servo motor.

[0024] In a second aspect, the application further provides a winding method based on the above-mentioned automatic spring winding torsion machine for windbreak curtains, which comprises the following steps:

[0025] Step (1), clamping and positioning: the outer roller of the windbreak curtain is clamped in place by the tool clamp, and the in-place signal is fed back to the PLC control system.

[0026] Step (2), parameter setting: input the target winding number of turns, torsion value and winding speed, and the PLC control system automatically checks the rationality of the parameters and stores them.

[0027] Step (3), winding operation: the PLC control system drives the driving device to operate according to the set parameters, and real-time data of the torsion sensor and the number of turns encoder are collected;

[0028] Step (4), unloading and resetting: after winding, the fixture clamp is loosened, the buckle mechanism is locked to prevent the square main shaft from returning, and the fixture clamp is reset to the state of waiting for clamping.

[0029] Preferably, in step (1), the displacement sensor on the fixture clamp monitors the clamping state in real time, and when the positioning error is less than or equal to 0.5 mm and the clamping deviation is less than or equal to 0.2 mm, a qualified signal is sent to the PLC control system.

[0030] Preferably, in step (3), when the number of turns reaches 90% of the target value, the speed is automatically reduced to 50%, and when the torsion fluctuation exceeds ±5%, the motor current is dynamically adjusted to maintain stable torsion.

[0031] Preferably, in step (3), the winding data is recorded throughout the process, and if there is clamping abnormality, torsion overrun or number of turns error, the machine stops immediately and stores fault information.

[0032] The automatic spring winding torsion machine and the winding method thereof provided by the present application take the PLC control system as the control center, receive and collect the number of turns, torsion and other data, and drive the driving device to operate accurately, while the encoder and the torsion sensor collect the motor pulse signal and the output shaft torsion in real time, the data is returned to the PLC to form a closed-loop control, realizing high-precision control of the number of turns and the torsion. Compared with the prior art, the present application has the following advantages:

[0033] (1) The control precision is significantly improved: through the closed-loop control system of PLC control system + servo motor + number of turns encoder + torsion sensor, the winding number error is less than or equal to 0.01 turns, and the torsion value fluctuation is less than or equal to ±5%, solving the technical problem of insufficient precision caused by manual adjustment of traditional equipment.

[0034] (2) Full-process automation and efficiency optimization: pneumatic or electric mechanism drives the fixture clamp to integrate automatic clamping, the positioning error is less than or equal to 0.5 mm, and automatic parameter verification can also be realized, supporting process library calling and dynamic process control, such as automatically reducing the speed to 50% when the number of turns reaches 90% of the target value, and dynamically adjusting the motor current when the torsion fluctuation exceeds ±5% to prevent overruns. The single-cycle production time is greatly shortened, the unloading and resetting time is very short, and the cost of manual intervention is reduced.

[0035] (3) Quality control and traceability capability enhancement: real-time collection of torsion, pulse signal (number of turns), automatic shutdown alarm and storage of fault information in abnormal conditions (such as torsion overrun ±5%), combined with batch traceability code and production data association mechanism, realizing full-process quality traceability.

[0036] (4) Improved process adaptability and stability: Supports adjustable parameters such as number of turns, torque and speed, and with the help of sensors and current dynamic adjustment technology (conventional current dynamic adjustment technology is sufficient) to ensure the stability of the winding process of torsion springs of different specifications.

[0037] (5) The automatic spring winding torque machine provided by this invention can automatically wind 350 turns with precision, stable torque, and a yield rate of ≥99%. Compared with traditional manual production, the yield rate is greatly improved (traditional manual production involves manually winding 120 turns, which is prone to counting errors and uneven torque, resulting in a yield rate of ≤85%). Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0039] In the diagram, 1. Electrical control box; 2. Servo motor; 3. Square sleeve; 4. Drive mechanism; 5. Tooling fixture; 6. Human-machine interface screen; 7. Clamping switch; 8. Power switch; 9. Manual button; 10. Automatic button; 11. Square spindle; 12. Outer roller.

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0041] In the description of this invention, it should be noted that the terms "upper", "lower", "inner", "outer", "top / bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0042] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0043] like Figure 1 As shown, the present invention provides an automatic windproof curtain spring winding torque machine, comprising:

[0044] The spring winding machine is a mechanical device specially used for manufacturing springs, and mainly functions to process metal wires (such as steel wires, copper wires, etc.) into various types of springs through bending, twisting and the like. In the present application, the spring winding machine is used for manufacturing torsion springs, and serves as a bearing device basic structure integrating a square main shaft 11 and a tool clamp 5 mounting position. Those skilled in the art can select a commonly used spring winding machine for manufacturing torsion springs according to actual needs, which is not specially limited here.

[0045] The PLC control system is preferably installed in the electric control box 1.

[0046] The driving device is mechanically connected to the square main shaft 11 of the spring winding machine, and drives the rotation of the square main shaft 11 to realize the winding of the torsion spring. In the present application, the driving device is preferably a servo motor 2, which is preferably located on one side of the spring winding machine. The servo motor 2 is used to provide stable power output, and the rotation speed can be adjusted within 0-100 r / min to ensure continuous and efficient winding process. The servo motor 2 receives the instructions of the PLC control system, and automatically stops rotating when the number of turns or the torsion trigger threshold is reached, and cooperates with the buckle mechanism to lock the square main shaft 11 to prevent backtracking.

[0047] The number of turns encoder is arranged at the shaft end of the driving device and rotates synchronously with the motor. The number of turns encoder is used to accurately record the rotation angle of the motor through pulse signals, and convert the rotation angle into the number of turns of the torsion spring. The rotation pulse signals of the driving device collected by the number of turns encoder are transmitted to the PLC control system, and the error is ≤0.01 turn.

[0048] The torsion sensor is arranged at the output shaft of the driving device, and is connected in series between the driving device and the square main shaft 11. The torsion sensor is used to collect torsion data in real time and return the torsion data to the PLC control system, and the accuracy is ±0.1 N·m. The torsion sensor can avoid the torsion fluctuation caused by uneven manual operation force.

[0049] In the present application, the following are further included:

[0050] The human-computer interaction screen 6 is used as an external operating panel of the device, and is in bidirectional communication with the PLC control system. The human-computer interaction screen 6 receives user input parameters and displays the running state of the device, such as real-time number of turns, torsion value, supports fault alarm and historical data query, etc. The setting of the human-computer interaction screen 6 simplifies the operation process. The worker only needs to select the product model, and automatically calls the parameters or manually inputs the parameters, and starts the device by one key.

[0051] The PLC control system is connected to the driving device, the number of turns encoder and the torsion sensor through a communication bus, so as to realize data interaction and instruction issuing. Specifically:

[0052] The PLC control system, as a control center, is used for receiving parameters such as the number of turns, the torsion, the rotating speed and the like input through the human-computer interaction screen 6, automatically checking rationality and storing. The driving servo motor 2 operates according to a set program, a closed loop control is formed through feedback data of the number of turns encoder and the torsion sensor, and precise winding is realized.

[0053] The PLC control system is also integrated with a process database, supports automatic calling of parameters of torsion springs of multiple specifications, and stores production data such as the number of turns, the torsion, the yield and the like for traceability.

[0054] In the application, the clamping and running mechanism of the tool clamp 5 in the spring winding machine is as follows: the square shaft of the workpiece to be processed is accurately inserted into the square sleeve 3 of the spring winding machine to complete mechanical positioning, after triggering the starting process, the PLC control system calls preset process parameters (or receives user instructions in real time), the driving device links the square main shaft 11, and completes the winding of the torsion spring according to the planned trajectory; wherein the square sleeve 3 clamp is adapted to square shafts of multiple specifications, and through a quick-change interface, clamping switching of different size shaft workpieces is realized, and the compatibility of the equipment is ensured. The tool clamp 5 is preferably installed on the workbench of the spring winding machine, is linked with the main body through the driving mechanism 4 (preferably a pneumatic or electric mechanism), and the clamping signal is fed back to the PLC control system through a line. The tool clamp 5 is linked with the spring winding machine through a pneumatic or electric mechanism, and is used for realizing rapid clamping of products.

[0055] In the application, the tool clamp 5 is provided with a displacement sensor, which is preferably integrated on the pneumatic or electric mechanism of the tool clamp 5 and is specifically installed near the positioning surface of the tool clamp 5 in contact with the square main shaft 11 of the torsion spring, and is used for monitoring the displacement deviation of the square main shaft 11 during clamping. It is preferably connected with the PLC control system through a signal line, and the displacement data of the tool clamp 5 is fed back to the control center in real time. It is linked with the pneumatic or electric mechanism of the tool clamp 5, and when the clamp performs clamping action, the displacement sensor starts monitoring synchronously. The clamping in-place state of the square main shaft 11 of the torsion spring is accurately monitored, the positioning error of the square concave-convex point of the tool clamp 5 and the square main shaft 11 of the torsion spring is ensured to be less than 0.2 mm, and the consistency of the winding reference is ensured. The signal of whether clamping is in place is fed back to the PLC control system as a prerequisite for starting the winding process; only when the sensor confirms that the clamping is qualified, the PLC allows the servo motor 2 to start. The setting of the displacement sensor eliminates the manual positioning error, replaces the traditional manual visual centering or simple mechanical limiting, avoids uneven distribution of the number of turns and the torsion of the torsion spring caused by clamping deviation. It can also improve the production stability, control the clamping deviation within 0.2 mm, unify the winding starting point of each batch of products, directly reduce the defective rate caused by reference deviation, make the yield of the automatic spring winding machine ≥99%, and significantly higher than the manual ≤85%.

[0056] The application also provides a winding method based on the above-mentioned windproof curtain automatic spring winding torsion machine.

[0057] Step (1), clamping positioning: the outer roller 12 of the windbreak curtain is placed into the tool clamp 5 and clamped in place, and a signal is fed back to the PLC control system. Specifically:

[0058] First, turn on the power switch 8 to power on the equipment, place the product to be processed in the tool clamp 5 stably, and ensure accurate positioning of the product; then align the square shaft 11 of the product with the square sleeve 3 of the spring winding machine and insert it into the square sleeve 3, completing the initial mechanical connection. Then press the clamping switch 7 to clamp and fix the outer roller 12 on the fixture to prevent it from rotating with the inner square shaft 11, and finally press the automatic button 10 to start the square shaft and torsional spring operation, and the signal is fed back to the PLC control system.

[0059] When the driving mechanism 4 selects a pneumatic mechanism, the air pressure of the pneumatic mechanism is set to 0.4-0.6 MPa.

[0060] The clamping position is monitored by a displacement sensor. When the clamping deviation is less than 0.2 mm, a "positioning signal" is sent to the PLC, triggering the subsequent process and ensuring the consistency of the winding reference. During the clamping process, the clamping force of the pneumatic mechanism or the electric mechanism can be fed back to the PLC control system through the pressure sensor to ensure that the clamping force is stable within the preset range and prevent the square shaft 11 from deforming or slipping.

[0061] Step (2), parameter setting: input the target winding turns, torsional force value and winding speed, and the PLC control system automatically checks the parameter rationality and stores it. Preferably, the parameters are input through the human-machine interaction screen 6. The PLC control system has a built-in multi-specification torsional spring process library (such as φ5mm, φ10mm torsional spring corresponding turn, torsional force parameters, etc.). After the operator selects the product model according to the needs, the appropriate parameters are automatically called to reduce manual input errors. The set parameters are automatically stored in the local database, associated with production batch information, and support historical parameter query and export.

[0062] Step (3), winding operation: the PLC control system drives the driving device to operate according to the set parameters, and real-time data of the torsional force sensor and the turn encoder are collected and fed back to the PLC control system. Specifically:

[0063] After confirming that the clamping is correct and the parameter setting is complete, click the manual button 9 or the automatic button 10. If automatic circulation is required, the automatic button 10 can be used after debugging in advance. The servo motor 2 drives the square shaft 11 to operate, and the spring winding process begins.

[0064] Automatic running, the PLC control system sends instructions, the servo motor 2 runs at the set speed, the number of turns encoder, the torque sensor synchronously collects data; when the number of turns reaches the set value or the torque triggers the threshold, the motor automatically stops, the buckle mechanism locks the square main shaft 11 to prevent back-off. Among them, the winding operation process can be dynamically controlled: during winding, the PLC control system compares the number of turns, torque data and the set value in real time: when the number of turns reaches 90%, automatically reduce to 50%, to ensure the accuracy of the end; when the torque fluctuation exceeds ± 5%, immediately adjust the motor current to maintain stable torque.

[0065] Step (4), unloading reset: after winding, the fixture clamp 5 is loosened, the buckle mechanism locks the square main shaft 11 to prevent back-off, and the fixture clamp 5 is reset to the waiting state for clamping, waiting for the next cycle.

[0066] The application also has data traceability management: each batch of production data, such as the number of turns, torque, yield, etc. is stored in the local database of the PLC control system, supporting U disk export, human-computer interaction screen 6 query, facilitating quality traceability and process optimization.

[0067] In the application, in step (1), the displacement sensor on the fixture clamp 5 monitors the clamping in-place state in real time, and sends an in-place qualified signal to the PLC control system when the positioning error is ≤0.5mm and the clamping deviation is ≤0.2mm.

[0068] In the application, in step (3), the winding data is recorded throughout the process, and if there is clamping abnormality, torque overrun or number of turns error, the machine will stop immediately and store fault information.

[0069] In summary, the above-mentioned windscreen automatic spring winding torque machine and the winding method thereof provided by the application have the following advantages:

[0070] Production efficiency: The automatic spring winding machine intelligently schedules through the PLC control system and the servo motor 2 runs continuously, reducing manual intervention and equipment downtime, and the production capacity is increased by about 192% compared with manual operation, which is suitable for large-scale production.

[0071] Quality precision: Abandoning manual and angle conversion error, the number of turns error is ≤0.01 turns, the torque control precision is ±0.1N·m, the product performance consistency is significantly improved, and the after-sales failure is effectively reduced.

[0072] Convenient operation: workers only need to clamp and set parameters, and the equipment can automatically complete winding with one key, reducing the requirement for manual skills and labor intensity, and reducing training cost.

[0073] Cost saving: The increase of yield reduces the waste of raw materials, the automatic operation reduces the labor cost, and the long-term use can significantly reduce the production cost.

[0074] The above merely describes preferred specific embodiments of the present application. The protection scope of the present application is not limited thereto, and any person skilled in the art can make equivalent replacements or changes to the technical solutions and improvement concepts of the present application within the technical scope disclosed by the present application, which should be covered by the protection scope of the present application.

Claims

1. A windscreen automatic spring-winding torsion machine, characterized in that, It comprises: a spring winding machine; a PLC control system; a driving device mechanically connected to the square shaft of the spring winding machine to drive its rotation and realize the winding of torsion spring; a number of turns encoder arranged at the shaft end of the servo motor and synchronously rotating with the motor to calculate the number of turns and transmit the collected rotation pulse signal of the driving device to the PLC control system; a torsion sensor arranged at the output shaft of the driving device and connected in series between the driving device and the square shaft to collect torsion data in real time and return to the PLC control system; the PLC control system is connected to the driving device, the number of turns encoder and the torsion sensor through a communication bus to realize data interaction and instruction issuing.

2. A windscreen automatic spring winding torque machine according to claim 1, characterized in that, It also comprises: a human-computer interaction screen in two-way communication with the PLC control system to receive user input parameters and display the running state of the equipment.

3. The windscreen automatic spring winding torque machine of claim 1, wherein, The clamping and running mechanism of the tool clamp in the spring winding machine is that the square shaft of the workpiece to be processed is inserted into the square sleeve of the spring winding machine to complete mechanical positioning, after triggering the starting process, the PLC control system calls the preset process parameters or receives user instructions in real time, the driving device drives the square shaft to complete the winding of torsion spring according to the planned trajectory.

4. The windscreen automatic winding spring torsion machine according to claim 3, characterized in that, A displacement sensor is arranged on the tool clamp in the spring winding machine to monitor the displacement deviation of the square shaft during clamping.

5. The windscreen automatic winding spring torsion machine according to claim 3, characterized in that, The tool clamp is linked with the spring winding machine through a pneumatic or electric mechanism to realize the quick clamping of the product.

6. A windscreen automatic spring winding torque machine according to any one of claims 1-5, characterized in that, The driving device is a servo motor.

7. A method of winding a windscreen according to any one of claims 1 to 6 by means of an automatic spring-winding torsion machine, characterized in that, It comprises the following steps: Step (1), clamping positioning: the outer roller of the windscreen is clamped in place by the tool clamp, and the in-place signal is fed back to the PLC control system; Step (2), parameter setting: input the target number of turns, torsion value and winding speed, and the PLC control system automatically checks the rationality of the parameters and stores them; Step (3), winding operation: the PLC control system drives the driving device to operate according to the set parameters, and collects data from the torsion sensor and the number of turns encoder in real time; Step (4), unloading and resetting: after winding, the tool clamp is loosened, the buckle mechanism locks the square shaft to prevent back-off, and the tool clamp is reset to the waiting clamping state.

8. A method of winding a windscreen automatic curtain spring according to claim 7, characterized in that, In step (1), the displacement sensor on the tool clamp monitors the clamping in-place state in real time, and sends an in-place qualified signal to the PLC control system when the positioning error is ≤0.5mm and the clamping deviation is ≤0.2mm.

9. A method of winding a windscreen automatic curtain spring according to claim 7, characterized in that, In step (3), when the number of turns reaches 90% of the target value, the speed is automatically reduced to 50%, and when the torsion fluctuation exceeds ±5%, the motor current is dynamically adjusted to maintain stable torsion.

10. A method of winding a windscreen automatic winding spring torsion machine according to any one of claims 7-9, characterized in that, In step (3), the winding data is recorded throughout the process, and if there is clamping abnormality, torsion overrun or number of turns error, the machine will stop and alarm immediately and store fault information.

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