A method for multi-station cycle time coordination control of a nickel starting sheet processing unit

Abstract

This invention belongs to the field of starting electrode processing technology in nickel electrolysis production. Specifically, it discloses a multi-station cycle time collaborative control method for a nickel starting electrode processing unit, including a PLC controller. The upstream five-in-one robotic arm cluster of the processing unit runs at a fixed cycle T0 to generate a reference cycle time source, synchronously completing stacking and feeding, double-sided shearing, 90° turning, secondary double-sided shearing, and transfer. The downstream three robotic arms of the processing unit are dynamically matched to complete the marking machine marking, ear-pinning of earpieces, and rod-threading and racking respectively. The upstream optimizes the reference cycle time source through physical layer cycle time, and the downstream performs dynamic matching through fluctuation suppression strategy, thereby improving the coordination between equipment.

Description

Technical Field

[0001] This invention belongs to the field of starting electrode processing technology in nickel electrolysis production, specifically relating to a multi-station cycle time collaborative control method for nickel starting electrode processing units. Background Technology

[0002] Nickel starter sheets are a key component in electrolytic nickel production, and their processing involves the coordination of multiple stations, including stacking and feeding, double-sided shearing, marking, stapling, and rod threading. Traditional processing units adopt a rigid assembly line layout, but suffer from unstable cycle times: when the cycle time of the preceding station is fast and that of the following station is slow, material tends to accumulate in the buffer area, and conversely, material shortages easily occur. This leads to frequent manual intervention, high labor intensity, and large cycle fluctuations due to the independent operation of each piece of equipment. Therefore, there is an urgent need for an automated cycle time coordination control method to achieve high stability operation of the entire line.

[0003] Therefore, it is necessary to design a multi-station cycle time collaborative control method for nickel starting electrode processing units to improve the coordination between equipment. Summary of the Invention

[0004] To address the problems of existing technologies, the purpose of this invention is to provide a multi-station cycle time coordinated control method for nickel starter sheet processing units, so as to solve the above-mentioned problems.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A multi-station cycle time collaborative control method for a nickel starting electrode processing unit includes a PLC controller. An upstream five-in-one robotic arm cluster runs at a fixed cycle T0 to generate a reference cycle time source, synchronously completing stacking and loading, bilateral shearing, 90° turning, secondary bilateral shearing, and transfer. Downstream three robotic arms dynamically match to complete marking by a marking machine, ear-pinning by an earpiece nailing machine, and rod threading and racking by a rod threading machine, respectively. The upstream unit optimizes the reference cycle time source through physical layer cycle time, and the downstream unit performs dynamic matching through a fluctuation suppression strategy.

[0006] More preferably, the physical layer cycle time is optimized for shearing using a large-aperture shearing machine.

[0007] More preferably, the fluctuation suppression strategy involves the label presser adjusting the feeding rhythm through the speed regulation of the lifting chain, the nail ear adjusting the folding frequency according to the label press outlet status, and the rod threading machine synchronizing the speed of the tilting device and the lifting chain.

[0008] More preferably, the PLC controller has built-in dynamic adjustment logic, which performs PID calculations based on the cycle deviation signal to correct the equipment parameters in real time.

[0009] More preferably, it also includes the abnormal operating condition cycle maintenance method.

[0010] Compared with the prior art, the present invention has the following advantages: 1. High cycle stability: The production cycle fluctuation of the entire line is ≤±5%, which solves the cycle deviation problem caused by the independent operation of traditional equipment.

[0011] 2. Strong fault tolerance: Production capacity is maintained at ≥85% in the event of a single point of failure, and the impact of downtime is reduced through bypass channels and in-situ freeze mechanisms.

[0012] 3. Good safety coordination: The recovery time of emergency stop events is reduced by 40%, and gravity equipment is locked first to avoid time-consuming reset.

[0013] 4. Enhanced adaptability: The large-aperture shearing machine design enhances its ability to handle bent and tilted plates; the redundant sorting mechanism prevents abnormal material blockage in the main process.

[0014] 5. High degree of automation: PLC closed-loop control reduces manual intervention, lowers labor intensity, and improves production efficiency. Attached Figure Description

[0015] Figure 1 This is a flowchart illustrating the overall layout of the nickel starting electrode processing unit of the present invention; Figure 2 This is a flowchart of the beat coordination control method of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0017] like Figure 1-2 The method for multi-station cycle time collaborative control of a nickel starting electrode processing unit is shown. It includes a PLC controller, an upstream five-in-one robot cluster that runs at a fixed cycle T0 to generate a reference cycle time source, and synchronously completes stacking and feeding, double-sided shearing, 90° turning, secondary double-sided shearing and transfer. Downstream three robots are dynamically matched to complete the marking machine marking, earphone nailing, and rod threading and racking respectively. The upstream uses physical layer cycle time optimization to optimize the reference cycle time source, and the downstream uses a fluctuation suppression strategy for dynamic matching.

[0018] The physical layer cycle time is optimized to use a large-aperture shearing machine for cutting, which shortens the idle time by increasing the idle speed and shortens the cycle time to within T0.

[0019] The fluctuation suppression strategy involves adjusting the feeding rhythm of the label presser by regulating the speed of the lifting chain, adjusting the folding frequency of the nail ear according to the label press outlet status, and synchronizing the speed of the tilting device and the lifting chain of the rod threading machine.

[0020] Adjustment of the labeling machine and lifting chain: The speed of the lifting chain at the labeling machine inlet is its core adjustment parameter. The lifting chain is equipped with a material detection sensor, and its speed is adjusted according to the occupancy rate of the buffer stations on the chain: if the buffer station is nearly full, the chain speed automatically decreases slightly below V0, down to 0.8 V0, to prevent blockage at the labeling machine inlet; if there are many empty buffer stations, the chain speed increases slightly above V0, up to 1.2 V0, ensuring a sufficient material supply to the labeling machine and avoiding material shortages. The goal is to maintain a stable material queue at the labeling machine inlet.

[0021] The earpiece monitors the material arrival signal at the labeling machine outlet and the material accumulation status in its own station buffer in real time. If it detects continuous material arrival and the buffer becomes longer, it automatically increases the earpiece frequency to consume the buffer faster. If the material arrival interval becomes longer or the buffer is emptied, it appropriately reduces the frequency to save energy and reduce wear, always dynamically matching the rhythm of the labeling machine outlet.

[0022] Adjustment of the rod threading machine: The core of the rod threading machine is to synchronize with the preceding process. The control system of the rod threading machine directly receives the "material ready" signal from the upstream (the headphone nailing completion station). Once the signal is received, the rod threading and tilting actions are started according to the timing synchronized with T0. The speed of the lifting chain is set according to the completion of the rod threading to ensure that the rod-threaded starter sheet can be smoothly and timely transported to the tilting and racking station to avoid accumulation at the rod threading machine outlet.

[0023] The PLC controller (Siemens S7-1215) has built-in dynamic adjustment logic. It performs PID calculations based on the cycle deviation signal, which is the deviation between the reference cycle T0 and the actual measured value of the robot's cycle T (ΔT = T – T0). The controller continuously monitors this cycle deviation. When the absolute value of the cycle deviation |ΔT| continuously exceeds the set threshold (±3% T0), the PID calculator starts to output a correction amount, calculating the speed correction coefficient for downstream equipment (such as lifting chain servo motors and headphone inverters). Small fluctuations within the set threshold are considered normal disturbances and are not adjusted to avoid frequent equipment operation, thereby achieving real-time correction of equipment parameters.

[0024] It also includes methods for maintaining cycle time under abnormal operating conditions. These methods include freezing the faulty unit and activating the bypass channel when equipment malfunctions. When the labeling machine malfunctions, it immediately freezes its upstream and downstream equipment to prevent material squeezing, while activating the preset return channel to reverse the lifting chain in front of the labeling station and send the starting sheet back to the upstream waste sheet station. In case of emergency shutdown, priority is given to locking gravity equipment with gravitational potential energy such as the labeling machine and shearing machine and freezing the robot arm in its original position. When materials are abnormal, redundant sorting is triggered to prevent the main process from being blocked.

[0025] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-station cycle time collaborative control method for a nickel starting electrode processing unit, comprising a PLC controller, an upstream five-in-one robotic arm cluster running at a fixed cycle T0 to generate a reference cycle time source, synchronously completing stacking and feeding, bilateral shearing, 90° turning, secondary bilateral shearing, and transfer; and downstream three robotic arms dynamically matching to respectively complete marking by the marking machine, ear-pinning of earpieces, and bar-threading and racking by the bar-threading machine, characterized in that: The upstream uses physical layer beat optimization to optimize the benchmark beat source, and the downstream uses a fluctuation suppression strategy for dynamic matching. The physical layer beat optimization uses a large-aperture shearing machine for cutting. The fluctuation suppression strategy involves the marking machine adjusting the feeding rhythm through the speed adjustment of the lifting chain, the nailing ear adjusting the folding frequency according to the marking outlet status, and the rod threading machine synchronizing the tilting device with the speed of the lifting chain.

2. The multi-station cycle time coordinated control method for a nickel starting electrode processing unit according to claim 1, characterized in that: The PLC controller has built-in dynamic adjustment logic, which performs PID calculations based on the cycle deviation signal to correct the equipment parameters in real time.

3. The multi-station cycle time coordinated control method for a nickel starting electrode processing unit according to claim 1, characterized in that: It also includes methods for maintaining cycle time under abnormal operating conditions.

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