Flying saw machine and stacking machine cooperative control system and method based on interconnection of double controllers

Abstract

The invention discloses a flying saw machine and stacking machine cooperative control system based on double-controller interconnection, the system comprises respective core control units, man-machine interaction units and execution mechanisms of a flying saw machine and a stacking machine, and respective core control units are respectively connected with respective man-machine interaction units and execution mechanisms; the core control unit of the flying saw machine and the core control unit of the stacking machine are in master-slave interconnection, the man-machine interaction unit of the flying saw machine can operate and control the flying saw machine and the stacking machine, and the man-machine interaction unit of the stacking machine can only operate and control the stacking machine. The invention further discloses a cooperative control method of the flying saw machine stacking machine cooperative control system based on double-controller interconnection. Full-function control over the stacking machine is achieved through the touch screen of the flying saw machine, and system collaboration and operation efficiency are improved. In a word, the operation flexibility is improved, the information synchronization is accurate, the labor cost is reduced, and the system fault tolerance is enhanced.

Description

Technical Field

[0001] This invention belongs to the field of straight seam welded pipe production technology, and particularly relates to a collaborative control system and method for flying saw and stacker based on dual controller interconnection. Background Technology

[0002] In the straight seam welded pipe production line, the fixed-length cutting by the flying saw and the orderly stacking by the stacker are the core processes to ensure production continuity.

[0003] Currently, in the welded pipe industry, flying saws and stackers generally adopt their own independent control modes: flying saws independently complete the setting of cutting parameters and start-stop operations, while stackers independently perform start-stop, mode switching, and parameter settings such as package type, number of pieces, and number of layers.

[0004] This independent control mode has significant technical shortcomings: First, there is insufficient operational coordination. The flying saw cutting and stacking require manual coordination, and operators need to frequently travel between the two machines or work in pairs. This can easily lead to pipe accumulation on the conveyor line due to asynchronous operation, causing production interruptions. Second, fault handling is delayed. When the stacker experiences malfunctions such as jamming or abnormal parameters, manual on-site inspection is required before feedback is sent to the flying saw side to stop the machine, which can easily lead to the accumulation of unprocessed pipes. Third, status monitoring is decentralized. The operating status and fault information of the flying saw and the stacker are displayed on their respective operating terminals. Managers need to travel back and forth to check in order to grasp the working conditions, which is not conducive to overall production scheduling and rapid problem location.

[0005] Currently, most existing linkage solutions in the welded pipe industry are based on simple signal triggers, which can only achieve a preliminary linkage between the start and stop of the flying saw and the start and stop of the stacker (relying only on electrical wiring, and only realizing simple operations such as power-on, power-off, and emergency stop). They cannot achieve synchronous parameter setting or mutual transmission of status between the two devices, and are difficult to adapt to the high-efficiency, precise and flexible control requirements of the production line. Therefore, there is an urgent need to develop an integrated technical solution that takes into account both the collaborative control of flying saw cutting and stacking and independent operation. Summary of the Invention

[0006] To address the aforementioned problems, the present invention aims to provide a collaborative control system and method for a flying saw stacker based on dual-controller interconnection, enabling full-function control of the stacker through the flying saw's touchscreen, thereby improving system collaboration and operational efficiency.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows: The collaborative control system for flying saws and stackers based on dual-controller interconnection includes core control units, human-machine interaction units, and actuators for both the flying saw and the stacker. The core control units of each flying saw are connected to their respective human-machine interaction units and actuators. The core control units of the flying saw and the stacker adopt a master-slave interconnection. The human-machine interaction unit of the flying saw can operate and control both the flying saw and the stacker, while the human-machine interaction unit of the stacker can only operate and control the stacker.

[0008] Furthermore, the core control unit adopts a PLC controller or a CT-III motion controller.

[0009] Furthermore, the two core control units are interconnected via a network cable using a protocol.

[0010] Furthermore, the two core control units are interconnected via a network cable using the TCP communication protocol.

[0011] Furthermore, the touchscreen of the flying saw is communicatively connected to the core control unit of the flying saw, and the touchscreen of the stacker crane is communicatively connected to the core control unit of the stacker crane.

[0012] Furthermore, the human-computer interaction unit is configured as a touch screen.

[0013] The collaborative control method using the aforementioned flying saw and stacker collaborative control system based on dual controller interconnection includes: the core control unit of the flying saw and the core control unit of the stacker are interconnected in a master-slave manner; the human-machine interaction unit of the flying saw can operate and control both the flying saw and the stacker; and the human-machine interaction unit of the stacker can only operate and control the stacker. Moreover, the information of the human-machine interaction units of the flying saw and the stacker is displayed synchronously.

[0014] Furthermore, the method includes: (1) Check the circuit before powering on the system; (2) When the system is powered on, the human-machine interaction unit of the flying saw and the human-machine interaction unit of the stacker are connected to the network and debugged, so that the core control unit of the flying saw and the core control unit of the stacker are interconnected. (3) Select the automatic operation mode or manual control mode of the flying saw through the human-machine interaction unit of the flying saw; (4) In the automatic operation mode or manual control mode of the flying saw, the stacker is operated and set through the human-machine interaction unit of the flying saw; (5) Once the system setup is complete, the flying saw and stacker start running, and the running information is displayed synchronously on the two human-machine interaction units.

[0015] Furthermore, in step (2): after network debugging through the human-machine interaction unit of the flying saw and the human-machine interaction unit of the stacker, when the network cable between the two core control units is disconnected, the communication between the two human-machine interaction units is interrupted, but the flying saw and the stacker maintain their previous states; after the network cable between the two core control units is restored, the communication between the two human-machine interaction units returns to normal, no parameters are lost, and the communication information is displayed synchronously.

[0016] This invention is an integrated technical solution that combines coordinated control of flying saw cutting and stacking with independent operation, and its specific advantages are as follows: (1) Improved operational flexibility: The touch screen on the flying saw side can operate and control both the flying saw and the stacker, while the touch screen on the stacker side can only operate and control the stacker, enabling different scenarios such as collaborative operation of the two devices and individual debugging. (2) Accurate information synchronization: The two controllers (flying saw side controller and stacker side controller) are interconnected via TCP master-slave to ensure that the instructions of the two touch screens are synchronized with the status of the actuator in real time, avoiding parameter input deviation and operation conflict, thereby adapting to the precise needs of the production line.

[0017] (3) Reduced labor costs: A single person can complete the entire process operation and control through the touch screen on the side of the flying saw, without the need to travel back and forth across areas or cooperate with two people; (4) Enhanced system fault tolerance: Dual touch screen redundancy design. When one touch screen fails, the other touch screen can ensure the normal operation of the stacker crane (e.g., if the flying saw side touch screen fails, the stacker side touch screen can also operate and control the stacker crane; if the stacker side touch screen fails, since the flying saw side touch screen can operate and control both the flying saw and the stacker crane, the flying saw side touch screen can also operate and control the stacker crane). Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the collaborative control system for the flying saw and stacker of the present invention. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to specific embodiments. Example 1:

[0020] Reference Figure 1 As shown, the collaborative control system for flying saw and stacker based on dual-controller interconnection in this embodiment includes the core control unit, human-machine interaction unit and actuator of each flying saw and stacker.

[0021] The core control unit uses a PLC controller (such as a Siemens PLC controller) or a CT-III motion controller (developed and publicly sold by our company).

[0022] The two controllers serve as the controllers for the flying saw and the stacker crane, respectively, and are interconnected via a network cable using the TCP communication protocol or other protocols.

[0023] The flying saw side controller and the stacker crane side controller are interconnected via TCP master-slave to ensure that the instructions of the two touch screens are synchronized with the status of the actuators in real time.

[0024] The human-computer interaction unit is a touch screen, including a fly saw side touch screen and a stacking side touch screen.

[0025] The touchscreen on the flying saw side can operate and control both the flying saw and the stacker crane (the two machines are interconnected through the controllers of the flying saw and the stacker crane, with the flying saw controller being the main controller. That is, the flying saw controller can send commands to the stacker crane controller via network communication to operate the stacker crane). The touchscreen on the stacker side can only operate and control the stacker crane, enabling different scenarios such as collaborative operation of the two machines and individual debugging.

[0026] Moreover, the touchscreen on the flying saw side can operate and control both the flying saw and the stacker crane, enabling full-function control of the stacker crane through the touchscreen on the flying saw side, thus improving the overall system coordination and operating efficiency.

[0027] The touchscreen on the flying saw side is connected to the controller of the flying saw, and the touchscreen on the stacker side is connected to the controller of the stacker.

[0028] In this embodiment, the structures of the saw-side touchscreen and the stack-side touchscreen adopt existing technologies, such as the Proface touchscreen.

[0029] The controller of the flying saw controls the flying saw actuator to perform the cutting of steel pipes; the controller of the stacker crane controls the stacker crane actuator to neatly stack the cut pipes. Example 2:

[0030] The method for collaborative control using the flying saw and stacker crane collaborative control system based on dual controller interconnection in this embodiment includes the following steps: I. Network debugging process for the above-mentioned collaborative control system: The first step, before powering on the system, is to check whether the power supply lines and communication lines are securely connected and whether the shielding layer is reliably grounded. The second step, after powering on, access the "Communication Parameters" settings interface on the flying saw side touchscreen. Set the IP address to "192.168.1.10", the subnet mask to "255.255.255.0", and the target IP to "192.168.1.12". Then access the "Communication Parameters" settings interface on the stacker side touchscreen, setting the IP address to "192.168.1.12", the subnet mask to "255.255.255.0", and the target IP to "192.168.1.10". This step sets the network parameters for both devices to establish a network connection.

[0031] (3) Third step, enter the “System Diagnosis” interface of the flying saw side touch screen, confirm that “TCP Communication Status” shows “Connected”, confirm that “Slave Online Status” shows “Normal”, and confirm that “Communication Status” of both the flying saw side touch screen and the stacking side touch screen shows “No Abnormality”.

[0032] (4) Fourth step, disconnect the network cable between the two controllers. The touch screen on the flying saw side displays "(communication interrupted)". The flying saw continues to run, and the stacker remains in its original state, but displays "(communication interrupted)". After the network cable between the two controllers is restored, the system automatically reconnects within 10 seconds. The communication between the flying saw and the stacker can be restored to normal, and no parameters are lost.

[0033] II. Operational procedures for the above-mentioned collaborative control system: First, start the flying saw. On the touch screen on the side of the flying saw, click the "Auto Run" button. A confirmation window will pop up. Once you confirm that the flying saw is working properly and all settings (pipe type, pipe diameter, set length, etc.) are ready, click "Confirm". The flying saw will then enter the automatic operation mode, and the touch screen on the side of the flying saw will display the automatic operation interface. The second step is to click the [Stacking Settings] option on the automatic operation interface of the aforementioned flying saw side touch screen to enter the stacking settings operation interface.

[0034] Third, click on [Bag Type Settings] to enter the bundle type configuration interface. Select according to the tube type, click on [Round Tube Bundle Type] (Standard Hexagonal Bundle or Custom Hexagonal Bundle) or [Square Tube Bundle Type], select the corresponding bundle type and set the total number of layers and the number of tubes in the first layer; return to the stacking settings operation interface.

[0035] Fourth step, click the [Start] button, and the stacker crane's frequency conversion motor, servo motor and oil pump will start synchronously; when the [Start] button turns green, it means that the start-up is complete and the crane has entered the ready state.

[0036] Fifth step, click the [Zero] button, and all servo axes of the stacker crane will perform a zero-position return action; when the [Zero] button turns green, the zero-position action is completed, and the equipment can proceed to subsequent operations.

[0037] Step 6: Click the [Auto] button. A confirmation window will pop up. After confirming that there are no abnormalities in the stacker crane, click OK. The stacker crane will then enter automatic operation mode.

[0038] Step 7: The flying saw stacker collaborative control system is now set up and can run automatically. Click the "Manual" button on the flying saw's automatic operation interface. After confirmation, the system will exit automatic mode and switch to manual control mode.

[0039] It should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any combination or equivalent transformation made based on the above embodiments shall fall within the scope of protection of the present invention.

Claims

1. A collaborative control system for flying saws and stackers based on dual-controller interconnection, characterized in that, The system includes a core control unit, a human-machine interface unit, and an actuator for each of the flying saw and the stacker. The core control unit of each flying saw is connected to its respective human-machine interface unit and actuator. The core control unit of the flying saw and the core control unit of the stacker are interconnected in a master-slave manner. The human-machine interface unit of the flying saw can operate and control both the flying saw and the stacker, while the human-machine interface unit of the stacker can only operate and control the stacker.

2. The collaborative control system for flying saws and stackers based on dual-controller interconnection as described in claim 1, characterized in that, The core control unit adopts a PLC controller or a CT-III motion controller.

3. The collaborative control system for flying saws and stackers based on dual-controller interconnection as described in claim 1 or 2, characterized in that, The two core control units are interconnected via a network cable using a protocol.

4. The collaborative control system for flying saws and stackers based on dual-controller interconnection as described in claim 3, characterized in that, The two core control units are interconnected via a network cable using the TCP communication protocol.

5. The collaborative control system for flying saws and stackers based on dual-controller interconnection as described in claim 1 or 2, characterized in that, The touchscreen of the flying saw is connected to the core control unit of the flying saw, and the touchscreen of the stacker crane is connected to the core control unit of the stacker crane.

6. The collaborative control system for flying saws and stackers based on dual-controller interconnection as described in claim 1 or 2, characterized in that, The human-computer interaction unit is a touch screen.

7. A collaborative control method using the flying saw / stacker collaborative control system based on dual-controller interconnection as described in claims 1-6, characterized in that, The method includes: the core control unit of the flying saw and the core control unit of the stacker are interconnected in a master-slave manner; the human-machine interaction unit of the flying saw can operate and control the flying saw and the stacker; the human-machine interaction unit of the stacker can only operate and control the stacker; and the information of the human-machine interaction units of the flying saw and the stacker is displayed synchronously.

8. The method as described in claim 7, characterized in that, The method includes: (1) Check the circuit before powering on the system; (2) When the system is powered on, the human-machine interaction unit of the flying saw and the human-machine interaction unit of the stacker are connected to the network and debugged, so that the core control unit of the flying saw and the core control unit of the stacker are interconnected. (3) Select the automatic operation mode or manual control mode of the flying saw through the human-machine interaction unit of the flying saw; (4) In the automatic operation mode or manual control mode of the flying saw, the stacker is operated and set through the human-machine interaction unit of the flying saw; (5) Once the system setup is complete, the flying saw and stacker start running, and the running information is displayed synchronously on the two human-machine interaction units.

9. The method as described in claim 8, characterized in that, Step (2): After network debugging through the human-machine interaction unit of the flying saw and the human-machine interaction unit of the stacker, when the network cable between the two core control units is disconnected, the communication between the two human-machine interaction units is interrupted, but the flying saw and the stacker maintain their previous states; after the network cable between the two core control units is restored, the communication between the two human-machine interaction units returns to normal, no parameters are lost, and the communication information is displayed synchronously.

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