Safety control method and system for printing roller of printing machine

Abstract

The invention relates to the technical field of safety control, and discloses a safety control method and system.The safety control method comprises the steps that when an independent mode is executed, parameter information of a target printing roller is obtained and verified firstly, it is guaranteed that speed control parameters are accurate, and the overspeed risk caused by parameter errors is avoided from the source; after the speed limiting button is triggered, the servo driving set is controlled to adjust the working state of the printing roller based on the verified parameters, it is ensured that actual operation meets the preset safe operation condition, and the personal safety of operators is remarkably improved by actively adjusting the speed in real time and effectively avoiding out-of-control overspeed; when the stop button is triggered, the preset linear deceleration algorithm is adopted to control the target printing roller to stop step by step instead of cutting off a whole machine power supply, mechanical impact caused by sudden power failure is avoided, the single mode is that stop operation is independently executed for the target printing roller, after stop, only the target printing roller needs to be restored to standby, and the whole machine does not need to be reset and restarted. The production interruption time is greatly shortened, and the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of safety control technology, and in particular to a method and system for safety control of printing press rollers. Background Technology

[0002] During the operation of a corrugated cardboard printing machine, processes such as hanging the printing plate and wiping the printing plate all require rotating the printing roller. Therefore, the safety of the roller operation is directly related to the personal safety of the operators and the production efficiency.

[0003] In existing technologies, printing rollers are typically driven by multi-speed control using conventional frequency converters. This means that different speed levels, such as low speed, medium speed, and high speed, are preset to drive the printing rollers. The safety protection mechanism relies on only two basic types of protection: conventional start-stop control under normal operating conditions, such as operators controlling the start or stop of all printing rollers via the control panel, and frequency converter fault protection, such as automatically cutting off the output to stop the printing rollers when the frequency converter detects internal faults such as overcurrent or overvoltage.

[0004] However, when abnormal situations such as encoder signal loss, control system failure, or electromagnetic interference cause the printing roller to run out of control and overspeed, conventional frequency converters cannot quickly form closed-loop control to cut off motor operation, which poses a serious threat to the personal safety of operators. Even if the operators trigger the emergency stop device in time to cut off the three-phase power supply of the whole machine, the three-phase power supply needs to be reset and restarted, which takes a long time and seriously affects the continuity and efficiency of production.

[0005] It is evident that existing technologies still need improvement and enhancement. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the purpose of this invention is to provide a safety control method for printing press rollers. By pre-calibrating parameters, active safety control, linear deceleration and stopping, and precise control in individual modes, this invention effectively solves the problems of runaway speed threatening personal safety, long restart time after emergency stop, and low operational accuracy in the prior art. It improves production continuity while ensuring operational safety.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A safety control method for printing press rollers is disclosed. The printing press roller safety control system includes a PLC controller, a servo drive group, a controlled execution group, a speed limit button, and a stop button. The speed limit button and the stop button are respectively connected to the input terminal of the PLC controller. The signal transmission terminal of the PLC controller is connected to the signal transmission terminal of the controlled execution group through the servo drive group. The printing press roller safety control method includes: when receiving an instruction to execute a separate mode, acquiring the identification information and parameter information of the target roller, and verifying and confirming the parameter information of the target roller, the parameter information including a safety limit speed threshold and a safe operating speed; when the speed limit button is triggered, based on the parameter information, controlling the servo drive group to adjust the working state of the target roller to ensure that the working state of the target roller meets the preset safe operating conditions; when the stop button is triggered, controlling the target roller to gradually stop working through the servo drive group using a preset linear deceleration algorithm.

[0008] In the aforementioned printing press roller safety control method, when an instruction to execute a separate mode is received, the identification information and parameter information of the target roller are acquired, and the parameter information of the target roller is verified and confirmed. The parameter information includes a safety limit speed threshold and a safe operating speed. This includes: acquiring the identification information and parameter information of the target roller when an instruction to execute a separate mode is received; the parameter information includes the panel parameter information of the servo drive group and the interface parameter information of the PLC controller; the panel parameter information and the interface parameter information respectively include a safety limit speed threshold and a safe operating speed; acquiring preset speed parameters based on the identification information; the preset speed parameters include a preset safety limit speed threshold and a preset safe operating speed; comparing the panel parameter information with the preset speed parameters once, and comparing the interface parameter information with the preset speed parameters a second time; when the results of the two comparisons are consistent, generating verification pass information to complete the verification and confirmation of the parameter information.

[0009] In the aforementioned printing press roller safety control method, when the results of two comparisons are consistent, an inspection pass information is generated. The method further includes: controlling the target roller to perform an unloaded test and acquiring the real-time rotational speed during the unloaded test; if the deviation between the real-time rotational speed and the preset safe operating speed is less than or equal to the preset allowable deviation threshold, an inspection pass information is generated.

[0010] In the aforementioned printing press roller safety control method, when the speed limit button is triggered, the step of controlling the servo drive group to adjust the working state of the target roller based on the parameter information to ensure that the working state of the target roller meets the preset safety operating conditions includes: when the speed limit button is triggered, obtaining the set rotation direction; based on the set rotation direction and the parameter information, sending control commands to the servo drive group through the SAFETYLINK safety communication module to adjust the running speed and rotation direction of the target roller, ensuring that the actual running speed of the target roller does not exceed the safety limit speed threshold and remains within the safe running speed range, and is consistent with the set rotation direction, thereby meeting the preset safety operating conditions.

[0011] In the aforementioned printing press roller safety control method, adjusting the operating speed and rotation direction of the target roller to ensure that the actual operating speed of the target roller does not exceed the safety limit speed threshold and remains within the safe operating speed range includes: acquiring the actual operating speed of the target roller through two independent speed sampling channels; when either speed sampling channel reports that the actual operating speed is greater than the safety limit speed threshold, reducing the actual operating speed to the safe operating speed through a PID adjustment module within a preset emergency adjustment time, controlling the servo drive group to reduce the actual operating speed to the safe operating speed, and monitoring the adjustment result in real time through the speed sampling channels to ensure that the actual operating speed of the target roller remains within the safe operating speed range and does not exceed the safety limit speed threshold.

[0012] In the aforementioned printing press roller safety control method, after real-time monitoring of the adjustment results through the speed feedback channel, the method further includes: monitoring the adjustment results for 10 consecutive preset sampling cycles through two independent speed sampling channels; if, in any of the 10 consecutive preset sampling cycles, the absolute value deviation between the actual operating speed and the safe operating speed in any preset sampling cycle exceeds a preset allowable deviation threshold, it indicates that the target roller is running unstable; a secondary stop command is sent to the servo drive group through the SAFETYLINK safety communication module, while simultaneously controlling the PID adjustment module to reduce the actual operating speed of the target roller to zero within a preset linear deceleration time.

[0013] In the aforementioned printing press roller safety control method, when the stop button is triggered, the target roller is gradually stopped by the servo drive group using a preset linear deceleration algorithm. This includes: when the stop button is triggered, sending a linear deceleration command to the servo drive group via the SAFETYLINK safety communication module; controlling the PID adjustment module to linearly reduce the actual operating speed of the target roller to zero within a preset linear deceleration time; when the actual operating speed of the target roller is zero, sending an electromagnetic brake command to the servo drive group via the SAFETYLINK safety communication module to lock the motor shaft of the target roller; exiting the standby mode and returning the target roller to standby mode.

[0014] The present invention also provides a printing press roller safety control system, wherein the printing press roller safety control system adopts any of the above-described printing press roller safety control methods to achieve operation control; the printing press roller safety control system includes a PLC controller, a servo drive group, a controlled execution group, a speed limit button and a stop button, wherein the speed limit button and the stop button are respectively connected to the input terminal of the PLC controller, the signal transmission terminal of the PLC controller is connected to the signal transmission terminal of the servo drive group through a SAFETYLINK safety communication module, and the servo drive group adjusts the working state of the printing press roller through the controlled execution group.

[0015] In the safety control system for the printing press roller, there are two stop buttons, which are respectively connected to the input terminal of the PLC controller. The speed limit button and the two stop buttons are dual-channel buttons.

[0016] In the aforementioned safety control system for printing press rollers, the servo drive group includes multiple servo drivers, each of which has a built-in dual-speed sampling channel; the controlled execution group includes multiple printing roller motors, each of which is used to drive the rotation of a corresponding target printing roller, and the multiple servo drivers are electrically connected to the multiple printing roller motors one-to-one.

[0017] Beneficial effects: This invention provides a safety control method for printing press rollers. In standby mode, the method first acquires and verifies the parameter information of the target roller to ensure accurate speed control parameters, thus preventing overspeed risks caused by incorrect parameters. After the speed limit button is triggered, the servo drive group adjusts the roller's working state based on the verified parameters, ensuring that actual operation meets preset safe operating conditions. Compared to existing technologies that rely solely on the inverter's own fault protection for passive protection, this solution actively and in real-time adjusts the speed, effectively preventing runaway speeding and significantly improving operator safety. When the stop button is triggered, a preset linear deceleration algorithm is used to gradually stop the target roller instead of cutting off the power to the entire machine, avoiding mechanical shock caused by sudden power outages. Furthermore, standby mode executes a stop operation only for the target roller; after stopping, only the target roller needs to return to standby mode, without requiring a complete machine reset and restart, significantly reducing production interruption time and improving production efficiency. Attached Figure Description

[0018] Figure 1 A logic flowchart of the printing press roller safety control method provided by the present invention; Figure 2 The present invention provides a system structure diagram of the printing press roller safety control system.

[0019] Explanation of main component symbols: 1-PLC controller, 2-servo drive group, 3-controlled execution group, 41-speed limit button, 42-stop button. Detailed Implementation

[0020] This invention provides a method and system for safety control of printing press rollers. To make the objectives, technical solutions and effects of this invention clearer and more explicit, the invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0021] In the description of this invention, it should be understood that the terms "installation" and "connection" should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0022] Please see Figure 1 This invention provides a safety control method for printing press rollers. The printing press roller safety control system includes a PLC controller 1, a servo drive group 2, a controlled execution group 3, a speed limit button 41, and a stop button 42. The speed limit button 41 and the stop button 42 are respectively connected to the input terminal of the PLC controller 1. The signal transmission terminal of the PLC controller 1 is connected to the signal transmission terminal of the controlled execution group 3 through the servo drive group 2. The printing press roller safety control method includes: 101. When receiving an instruction to execute a separate mode, obtain the identification information and parameter information of the target printing roller, and verify and confirm the parameter information of the target printing roller, wherein the parameter information includes the safety limit speed threshold and the safe operating speed; In this embodiment, when the PLC controller 1 receives an instruction to execute the standalone mode, such as when the operator selects the standalone mode and chooses the target printing roller on the interface of the PLC controller 1, the PLC controller 1 first obtains the identification information of the target printing roller, such as the printing roller ID, and the parameter information, and then verifies the parameter information to ensure that the parameter information is correct.

[0023] 102. When the speed limit button 41 is triggered, based on the parameter information, the servo drive group 2 is controlled to adjust the working state of the target printing roller to ensure that the working state of the target printing roller meets the preset safe operating conditions. In this embodiment, when the operator presses the speed limit button 41, the PLC controller 1 sends a command to the servo drive group 2 based on the verified parameter information to adjust the working state of the target printing roller, including the speed and rotation direction, so as to finally meet the preset safe operating conditions. The preset safe operating conditions are a combination of speed safety and direction safety, that is, the actual speed is ≤ the safe speed limit threshold Vm, the actual speed is = the safe operating speed Vs, and the rotation direction is consistent with the operator's setting.

[0024] In this embodiment, addressing the problem of abnormal overspeed response delay caused by traditional frequency converters relying on basic fault protection and lacking a real-time closed-loop control mechanism, this method achieves millisecond-level response to overspeed risks through parameter verification pre-set and coordinated closed-loop control of servo drive group 2, fundamentally eliminating personnel safety hazards caused by speed runaway.

[0025] 103. When the stop button 42 is triggered, the target printing roller is gradually stopped by the servo drive group 2 using a preset linear deceleration algorithm. In this embodiment, when the stop button 42 is pressed, the PLC controller 1 sends a linear deceleration command to the servo drive group 2 through the SAFETYLINK safety communication module, starts the preset linear deceleration algorithm, controls the target printing roller to gradually decrease from the current speed to a stop, so that the output torque smoothly and linearly decreases from 80% of the rated torque to 0, and the actual running speed decreases linearly from the current running speed to 0 for a preset linear deceleration time of 1-2 seconds, effectively avoiding motor overload and brake mechanical wear caused by sudden stop impact, and significantly extending the service life of the controlled execution group 3.

[0026] This application discloses a safety control method for printing press rollers. In standby mode, the parameter information of the target roller is first acquired and verified to ensure that the speed control parameters are accurate, thus avoiding the risk of overspeed due to parameter errors. After the speed limit button 41 is triggered, the servo drive group 2 is controlled to adjust the working state of the roller based on the verified parameters to ensure that the actual operation meets the preset safe operating conditions. Compared with the passive protection of the existing technology that relies only on the fault protection of the frequency converter itself, this technical solution effectively avoids runaway speeding by actively and in real time adjusting the speed, significantly improving the personal safety of operators. When the stop button 42 is triggered, a preset linear deceleration algorithm is used to control the target roller to stop gradually, rather than cutting off the power supply of the whole machine, avoiding mechanical impact caused by sudden power failure. Moreover, the standby mode is to perform the stop operation separately for the target roller. After stopping, only the target roller needs to be restored to standby mode, without the need for the whole machine to be reset and restarted, which greatly shortens the production interruption time and improves production efficiency.

[0027] In this embodiment of the invention, when an instruction to execute a separate mode is received, the identification information and parameter information of the target printing roller are obtained, and the parameter information of the target printing roller is verified and confirmed. The parameter information includes a safety limit speed threshold and a safe operating speed, including: 201. When receiving an instruction to execute a separate mode, obtain the identification information and parameter information of the target printing roller. The parameter information includes the panel parameter information of the servo drive group 2 and the interface parameter information of the PLC controller 1. The panel parameter information and the interface parameter information respectively include the safety limit speed threshold and the safe operating speed. 202. Based on the identification information, obtain the preset speed parameters, which include a preset safety limit speed threshold and a preset safe operating speed; In this embodiment, the preset speed parameters are pre-configured by technicians based on factors such as the printing roller diameter, operating scenario, and motor power, and stored in the parameter database of PLC controller 1. After obtaining the parameter information, the system calls the preset speed parameters based on the identification information of the target printing roller, including the preset safety limit speed threshold Vm and the preset safe operating speed Vs.

[0028] 203. Compare the panel parameter information with the preset speed parameters once, and compare the interface parameter information with the preset speed parameters a second time; 204. When the results of the two comparisons are consistent, a verification pass message is generated to complete the verification and confirmation of the parameter information; In this embodiment, the panel parameters of the servo drive are compared with the preset speed parameters in the first comparison, and the interface parameters of the PLC controller 1 are compared with the preset speed parameters in the second comparison. Only when the two comparison results are completely consistent will a verification pass message be generated, allowing subsequent operations to proceed. If either comparison is inconsistent, an audible and visual alarm will be triggered immediately, and the interface of the PLC controller 1 will display "Parameters inconsistent, please reset". The operator needs to recalibrate the parameters and verify again. By comparing parameters from two sources, parameter configuration errors are avoided from the source, and the comparison covers the hardware parameters of the servo drive and the software parameters of the PLC controller 1, avoiding deviations in single-source parameters due to interference or malfunction.

[0029] In this embodiment of the invention, when the two comparison results are consistent, generating verification pass information, the method further includes: 301. Control the target printing roller to perform an unloaded test and obtain the real-time rotation speed during the unloaded test process; 302. If the deviation between the real-time rotational speed and the preset safe operating speed is less than or equal to the preset allowable deviation threshold, then a test pass message is generated; In this embodiment, after the parameter verification is passed, the no-load test of the target printing roller is automatically triggered. The no-load test duration is usually 30-60 seconds to ensure stable rotation speed and avoid misjudgment caused by short-term fluctuations. During the no-load test, the real-time rotation speed of the target printing roller is collected in real time. The real-time rotation speed is obtained through the rotation speed sampling channel of the servo drive group 2. If the deviation between the real-time rotation speed and the preset safe operating speed is ≤ the preset allowable deviation threshold, a test pass information is generated, allowing entry into formal operation. The preset allowable deviation threshold is ±5%. If the real-time rotation speed deviation is > ±5%, an alarm is triggered, and the following troubleshooting items are displayed on the interface of the PLC controller 1: 1. Whether the wiring between the servo drive and the motor is loose; 2. Whether the motor bearing is stuck; 3. Whether the rotation speed sampling channel is faulty.

[0030] In this embodiment, even if the parameters are correct, hardware abnormalities can still lead to safety risks. No-load testing can detect problems with the motor, servo driver, and speed sampling channel in advance, avoid sudden failures during operation, ensure stable speed during formal operation, reduce downtime caused by hardware or parameter problems during operation, and improve production continuity.

[0031] In this embodiment of the invention, when the speed limit button 41 is triggered, based on the parameter information, the servo drive group 2 is controlled to adjust the working state of the target printing roller to ensure that the working state of the target printing roller meets the preset safe operating conditions, including: 401. When the speed limit button 41 is triggered, the set rotation direction is obtained; 402. Based on the set rotation direction and the parameter information, a control command is sent to the servo drive group 2 through the SAFETYLINK safety communication module to adjust the running speed and rotation direction of the target printing roller, ensuring that the actual running speed of the target printing roller does not exceed the safety limit speed threshold and is maintained within the safe running speed range, and is consistent with the set rotation direction, thereby meeting the preset safe operating conditions. In this embodiment, after the speed limit button 41 is triggered, the rotation direction set by the operator is obtained through the interface of the PLC controller 1. The rotation direction includes forward and reverse rotation. Then, based on the set rotation direction and the verified parameter information, a control command is sent to the servo drive group 2 through the SAFETYLINK safety communication module. The servo drive group 2 executes the control command to adjust the running speed and rotation direction of the target printing roller, ultimately meeting the preset safe operating conditions. During this adjustment process, only the target printing roller responds to the speed limit button 41 command, while other printing rollers remain in standby mode. This avoids the risk of misoperation caused by multi-roller linkage in the prior art, adapts to the scenario of single-person single-roller operation, and improves operational flexibility.

[0032] In real-world scenarios, once the rotation direction is set, if the direction needs to be changed during operation, the speed limit button 41 must be released first, the direction must be selected again, and the button must be triggered again to avoid sudden changes in direction caused by accidental touch of the direction button. During operation, the interface of PLC controller 1 displays the actual running speed, rotation direction, and Vm / Vs value in real time, allowing operators to intuitively confirm whether the safety conditions are met and reducing the rate of operational errors.

[0033] In this embodiment of the invention, adjusting the operating speed and rotation direction of the target printing roller to ensure that the actual operating speed of the target printing roller does not exceed the safety limit speed threshold and remains within the safe operating speed range includes: 501. Obtain the actual running speed of the target printing roller through two independent speed sampling channels; In this embodiment, the speed of the printing roller motor is collected by two independent speed sampling channels built into the servo drive group 2, and the actual running speed of the target printing roller is obtained in real time. The two speed sampling channels work independently. Even if one speed sampling channel fails, the other speed sampling channel can still collect the speed normally, avoiding overspeed missed detection caused by single channel failure and ensuring that there are no blind spots in overspeed monitoring.

[0034] 502. When any speed sampling channel feeds back the actual operating speed > the safety limit speed threshold, the PID adjustment module reduces the actual operating speed to the safe operating speed within a preset emergency adjustment time, controls the servo drive group 2 to reduce the actual operating speed to the safe operating speed, and monitors the adjustment result in real time through the speed sampling channel to ensure that the actual operating speed of the target printing roller is maintained within the safe operating speed range and does not exceed the safety limit speed threshold. In this embodiment, if any speed sampling channel feeds back an actual operating speed > Vm, the PID adjustment module is immediately triggered to make dynamic adjustments. Specifically, the PID adjustment module of PLC controller 1 controls the servo drive group 2 to reduce the actual operating speed to the safe operating speed Vs within a preset emergency adjustment time. The preset emergency adjustment time is 10ms, which makes the target printing roller respond much faster than the human body, ensuring that the speed reduction protection is completed before personnel come into contact with the dangerous area.

[0035] In existing technologies, frequency converters rely on basic fault protection and lack real-time closed-loop control mechanisms. This application achieves millisecond-level overspeed response by using dual speed sampling channels in conjunction with a PID adjustment module. This can instantly pull the speed back to a safe range during abnormal speed events, fundamentally eliminating the risk of personal injury. Compared to traditional step speed reduction, the linear speed reduction characteristics of the PID adjustment module can not only avoid excessive temperature rise and insulation damage to the printing roller motor caused by overspeed, but also prevent motor overload and mechanical shock caused by sudden speed drops, significantly extending the service life of the printing roller motor.

[0036] In this embodiment of the invention, the step of monitoring the adjustment result in real time through the speed feedback channel further includes: monitoring the adjustment result for 10 consecutive preset sampling cycles through two independent speed sampling channels; 601. If, in any of the 10 consecutive preset sampling cycles, the absolute value deviation between the actual operating speed and the safe operating speed in any preset sampling cycle exceeds the preset allowable deviation threshold, it indicates that the target printing roller is running unstable. 602. Send a secondary stop command to servo drive group 2 through SAFETYLINK safety communication module, and at the same time control PID adjustment module to reduce the actual running speed of the target printing roller to zero within the preset linear deceleration time. In this embodiment, after the target printing roller decelerates to the safe operating speed Vs, the adjustment result is continuously monitored for 10 preset sampling cycles through two speed sampling channels. Each sampling cycle is 1ms, and the total monitoring time is 10ms. If the absolute value deviation between the actual operating speed and the safe operating speed Vs in any of the 10 sampling cycles is greater than or equal to the preset allowable deviation threshold, the target printing roller is determined to be unstable. The PLC controller 1 sends a secondary stop command to the servo drive group 2 through the SAFETYLINK safety communication module, and at the same time controls the PID adjustment module to linearly reduce the actual operating speed to zero within a preset linear deceleration time, which is 1-2s.

[0037] In actual operation scenarios, unstable speed may stem from various factors, such as motor failure, servo drive parameter drift, and load fluctuations. A two-stage stop is necessary to prevent the fault from escalating. A regular stop is an active stop after the work is completed, while a two-stage stop is a passive fallback stop in fault scenarios. Although both use linear deceleration, the two-stage stop has a stronger brake locking force. Triggering a two-stage stop automatically records fault information, facilitating subsequent troubleshooting. Therefore, the technical solution in this application not only solves the overspeed problem but also provides fallback protection against the hidden risks of instability after speed reduction, achieving comprehensive safety protection. By promptly stopping the unstable printing roller, further damage to the motor and wear on mechanical components can be prevented, significantly reducing maintenance costs. Simultaneously, by automatically recording fault information, troubleshooting time is greatly shortened, improving equipment maintenance efficiency.

[0038] In this embodiment of the invention, when the stop button 42 is triggered, the target printing roller is gradually stopped by the servo drive group 2 using a preset linear deceleration algorithm, including: 701. When the stop button 42 is triggered, a linear deceleration command is sent to the servo drive group 2 through the SAFETYLINK safety communication module; 702. The PID control module linearly reduces the actual running speed of the target printing roller to zero within a preset linear deceleration time. 703. When the actual running speed of the target printing roller is zero, an electromagnetic brake command is sent to the servo drive group 2 through the SAFETYLINK safety communication module to lock the motor shaft of the target printing roller. 704. Exit standby mode; the target printing roller returns to standby mode. In this embodiment, when the stop button 42 is triggered, the PLC controller 1 sends a linear deceleration command to the servo drive group 2 through the SAFETYLINK safety communication module. At this time, the PID adjustment module linearly reduces the actual running speed of the target printing roller to zero within the preset linear deceleration time. When the actual running speed drops to zero, the PLC controller 1 sends an electromagnetic brake command to the servo drive group 2. The servo drive group 2 controls the electromagnetic brake of the printing roller motor to be energized, locking the motor shaft and preventing the target printing roller from rotating due to inertia. After the brake is locked, it automatically exits the standby mode and the target printing roller returns to the standby mode. In the standby mode, the servo drive group 2 is in a low-power state and does not respond to the speed limit button 41 command, only receiving mode activation or fault diagnosis commands. In addition, after the brake is locked, the operator needs to click "unlock brake" on the interface of the PLC controller 1 and reactivate the standby mode to avoid accidentally touching the start button and causing the printing roller to rotate suddenly. The preset linear deceleration time is 1-2 seconds and is related to the motor power. Specifically, the greater the motor power, the longer the deceleration time, to avoid power grid fluctuations caused by a sudden drop in torque.

[0039] In this embodiment, when the stop button 42 is triggered, the PLC controller 1's linear deceleration algorithm, combined with the electromagnetic brake's dual protection mechanism, can avoid excessive wear of the brake and roller rotation due to inertia caused by emergency stops in the prior art, effectively protecting the printing roller motor and transmission components. After exiting the standby mode, the PLC controller 1 automatically cuts off the servo drive enable, so even if the speed limit button 41 is accidentally pressed, the printing roller will not start, further improving operational safety. In standby mode, it supports quick activation of the standby mode or seamless switching to the whole machine linkage mode, significantly improving production switching efficiency.

[0040] Please see Figure 2 The present invention also provides a printing press roller safety control system, wherein the printing press roller safety control system adopts any of the above-described printing press roller safety control methods to achieve operation control; the printing press roller safety control system includes a PLC controller 1, a servo drive group 2, a controlled execution group 3, a speed limit button 41, and a stop button 42, wherein the speed limit button 41 and the stop button 42 are respectively connected to the input terminal of the PLC controller 1, the signal transmission terminal of the PLC controller 1 is connected to the signal transmission terminal of the servo drive group 2 through a SAFETYLINK secure communication module, and the servo drive group 2 adjusts the working state of the printing press roller through the controlled execution group 3.

[0041] The printing press roller safety control system disclosed in this application can be adapted to corrugated cardboard printing presses of different specifications, such as 3-roll and 5-roll models, requiring only the addition of servo drivers and motors; the PLC controller 1 and the servo control group feedback status information through the SAFETYLINK safety communication module, and the interface of the PLC controller 1 can display the fault location in real time, facilitating rapid maintenance.

[0042] In this embodiment, the PLC controller 1 is a ctrlX SAFTY PLC.

[0043] Furthermore, the stop button 42 includes two buttons, which are respectively connected to the input terminal of the PLC controller 1. The speed limit button 41 and the two stop buttons 42 are dual-channel buttons.

[0044] In this embodiment, two independent stop buttons 42 are configured. Both stop buttons 42 are connected to the input terminal of the PLC controller 1 and are triggered by OR logic. That is, when any stop button 42 is triggered or both stop buttons 42 are triggered simultaneously, a stop command can be sent to the servo drive group 2. The speed limit button 41 and the two stop buttons 42 are both dual-channel buttons, that is, each button contains two independent signal contacts, which are respectively connected to two different input channels of the PLC controller 1, forming a signal redundancy safety mechanism to avoid command transmission failure due to single-channel failure and ensure signal transmission reliability. In addition, when the dual-channel signals are inconsistent, an alarm is automatically triggered, which facilitates the early replacement of faulty buttons and avoids button failure in emergency situations. The two stop buttons 42 are respectively installed in the safety areas on both sides of the printing roller, such as the left and right operation boxes, so that the operator can trigger them nearby to improve the response speed in emergency situations, meet the needs of single-person single-side operation or double-person double-side operation, and significantly improve the convenience of operation and emergency response efficiency.

[0045] Furthermore, the servo drive group 2 includes multiple servo drivers, each of which has a built-in dual-speed sampling channel; the controlled execution group 3 includes multiple printing roller motors, each of which is used to drive the rotation of a corresponding target printing roller, and the multiple servo drivers are electrically connected to the multiple printing roller motors one-to-one. In this embodiment, each servo driver independently receives instructions from PLC controller 1 and independently controls the corresponding printing roller motor. In standalone mode, if a servo driver fails, only the printing roller corresponding to the failed servo driver is affected, while other printing rollers can still start normally, avoiding a complete shutdown due to a single failure and improving production continuity. Each servo driver has a built-in dual speed sampling channel, such as two independent incremental encoder interfaces, which can collect the speed of the corresponding printing roller motor in real time, realize redundant monitoring, ensure that there are no blind spots in the speed monitoring of all printing rollers, and fully guarantee operational safety.

[0046] It is understood that those skilled in the art can make equivalent substitutions or changes to the technical solution and inventive concept of the present invention, and all such changes or substitutions should fall within the protection scope of the present invention.

Claims

1. A method of safety control of a printing press printing roller, characterized in that, The printing machine roller safety control system comprises a PLC controller, a servo drive group, a controlled execution group, a speed limiting button and a stop button, the speed limiting button and the stop button are connected with the input end of the PLC controller respectively, and the signal transmission end of the PLC controller is connected with the signal transmission end of the controlled execution group through the servo drive group; The printing machine roller safety control method comprises: When receiving an instruction to execute a single mode, the identification information and parameter information of the target roller are obtained, and the parameter information of the target roller is verified and confirmed, the parameter information comprising a safety limit speed threshold and a safety running speed; When the speed limiting button is triggered, the working state of the target roller is adjusted by the servo drive group based on the parameter information, to ensure that the working state of the target roller meets the preset safety operation condition; When the stop button is triggered, the target roller is gradually stopped working by using a preset linear deceleration algorithm through the servo drive group.

2. A method of safety control of a printing roller of a printing machine according to claim 1, characterized in that, When receiving an instruction to execute a single mode, the identification information and parameter information of the target roller are obtained, and the parameter information of the target roller is verified and confirmed, the parameter information comprising a safety limit speed threshold and a safety running speed, comprising: When receiving an instruction to execute a single mode, the identification information and parameter information of the target roller are obtained, the parameter information comprising panel parameter information of the servo drive group and interface parameter information of the PLC controller, the panel parameter information and the interface parameter information comprising a safety limit speed threshold and a safety running speed respectively; Based on the identification information, a preset speed parameter is obtained, the preset speed parameter comprising a preset safety limit speed threshold and a preset safety running speed; The panel parameter information is compared with the preset speed parameter once, and the interface parameter information is compared with the preset speed parameter twice; When the results of the two comparisons are consistent, verification pass information is generated to complete the verification and confirmation of the parameter information.

3. A method of safety control of a printing roller of a printing machine according to claim 2, characterized in that, When the results of the two comparisons are consistent, verification pass information is generated, and then the method further comprises: The target roller is controlled to perform a no-load test, and the real-time rotating speed in the no-load test process is obtained in real time; If the deviation between the real-time rotating speed and the preset safety running speed is less than or equal to a preset allowable deviation threshold, test pass information is generated.

4. The method of claim 1, wherein, When the speed limiting button is triggered, the working state of the target roller is adjusted by the servo drive group based on the parameter information, to ensure that the working state of the target roller meets the preset safety operation condition, comprising: When the speed limiting button is triggered, the set rotating direction is obtained; Based on the set rotating direction and the parameter information, a control instruction is sent to the servo drive group through a SAFETYLINK safety communication module to adjust the running speed and rotating direction of the target roller, to ensure that the actual running speed of the target roller does not exceed the safety limit speed threshold and is maintained within the safety running speed range, and is consistent with the set rotating direction, thereby meeting the preset safety operation condition.

5. A method of safety control of a printing roller of a printing machine according to claim 4, characterized in that, The adjustment of the running speed and rotation direction of the target printing roller ensures that the actual running speed of the target printing roller does not exceed the safety limit speed threshold and is maintained within the safe running speed range, comprising: The actual running speed of the target printing roller is obtained through two independent speed sampling channels; When any speed sampling channel feeds back that the actual running speed is greater than the safety limit speed threshold, the actual running speed is reduced to the safe running speed within a preset emergency adjustment time through the PID adjustment module, the actual running speed is reduced to the safe running speed by the servo drive group, and the adjustment result is monitored in real time through the speed sampling channel to ensure that the actual running speed of the target printing roller is maintained within the safe running speed range and does not exceed the safety limit speed threshold.

6. A method of safety control of a printing roller of a printing machine according to claim 5, characterized in that, The adjustment result is monitored in real time through the speed feedback channel, and then further comprising: The adjustment result of 10 consecutive preset sampling periods is monitored through two independent speed sampling channels; If the absolute value deviation between the actual running speed and the safe running speed in any preset sampling period in the adjustment result of 10 consecutive preset sampling periods is greater than the preset allowed deviation threshold, it indicates that the target printing roller is unstable; A two-level stop instruction is sent to the servo drive group through the SAFETYLINK safety communication module, and the PID adjustment module is controlled to reduce the actual running speed of the target printing roller to zero within a preset linear deceleration time.

7. The method of claim 1, wherein, When the stop button is triggered, the target printing roller is gradually stopped working by the servo drive group using a preset linear deceleration algorithm, comprising: When the stop button is triggered, a linear deceleration instruction is sent to the servo drive group through the SAFETYLINK safety communication module; The PID adjustment module is controlled to linearly reduce the actual running speed of the target printing roller to zero within a preset linear deceleration time; When the actual running speed of the target printing roller is zero, an electromagnetic brake instruction is sent to the servo drive group through the SAFETYLINK safety communication module to lock the motor shaft of the target printing roller; Exit the single mode, and the target printing roller returns to the standby mode.

8. A printing press inking roller safety control system characterized by, The printing machine roller safety control system realizes work control by using the printing machine roller safety control method according to any one of claims 1-7; the printing machine roller safety control system comprises a PLC controller, a servo drive group, a controlled execution group, a speed limit button and a stop button, the speed limit button and the stop button are respectively connected with the input end of the PLC controller, the signal transmission end of the PLC controller is connected with the signal transmission end of the servo drive group through the SAFETYLINK safety communication module, and the servo drive group adjusts the working state of the printing roller through the controlled execution group.

9. A safety control system for a printing press printing roller as defined in claim 8, characterized in that, The stop button comprises two, and the two stop buttons are respectively connected with the input end of the PLC controller, and the speed limit button and the two stop buttons are respectively double-channel buttons.

10. A safety control system for a printing press printing roller as defined in claim 8, wherein, The servo drive group comprises a plurality of servo drives, each of which is internally provided with double rotation speed sampling channels; the controlled execution group comprises a plurality of printing roller motors, each of which is used to drive the rotation of a corresponding target printing roller, and the plurality of servo drives are electrically connected to the plurality of printing roller motors one by one.

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