Plate follow-up circular processing and automatic stacking production line and control method

Abstract

The invention relates to the technical field of laser cutting, in particular to a plate follow-up circular machining and automatic stacking production line and a control method. The method comprises the steps that a synchronous control process is executed, and the plate conveying speed is fed back in real time based on a fixed-length measuring device; the feeding speed of the leveling machine is kept synchronous with the rolling speed of a roller conveying table top of the laser cutting machine; executing a path tracking control process to control a laser cutting head to accurately track and cut the dynamically conveyed plate; a tension control process is executed, so that the tension of the plate between the uncoiling machine and the leveling machine is stabilized within a preset range by adjusting the uncoiling torque of the uncoiling machine and the rolling reduction of the roller set of the leveling machine; and a stacking control process is executed so as to respond to a material arrival signal sent by an induction photoelectric switch at the tail of the synchronous material detection platform, and a material picking and stacking device is controlled to suck the cut plates or parts and stack the cut plates or parts. The machining precision of follow-up cutting is guaranteed, and the stability of the machining process and the product quality are guaranteed.

Description

Technical Field

[0001] This application relates to the field of laser cutting technology, specifically to a sheet metal follow-up circulation processing and automatic palletizing production line and control method. Background Technology

[0002] In the field of sheet metal processing, the production of steel coils into final parts or complete sheets typically involves multiple processes, including uncoiling, leveling, cutting, and subsequent material handling and stacking. Currently, while mainstream equipment on the market has achieved mechanization in some stages, it still falls short in terms of overall automation, processing efficiency, and intelligence, thus hindering further improvements in production efficiency.

[0003] Traditional production methods typically consist of discrete units such as uncoiling and leveling machines, laser cutting machines, and unloading areas, lacking efficient linkage and coordination between these units. In the traditional model, after the steel coil is uncoiled and leveled, the sheet material must be intermittently fed to the laser cutting machine's worktable, and cutting can only begin after the machine has completely stopped. This cycle of "feeding-stopping-cutting-refeeding" results in a significant amount of non-processing waiting time, drastically reducing the effective working time of the laser cutting machine and making it difficult to improve the overall processing efficiency of the production line.

[0004] Therefore, there is an urgent need in this field for an automated solution that can integrate the entire process of uncoiling, leveling, cutting and palletizing, achieve continuous, synchronous and efficient production, and intelligently adapt to different cut finished products. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a production line and control method for sheet metal follow-up cyclic processing and automatic palletizing.

[0006] In a first aspect, the technical solution of the present invention provides a sheet metal follow-up circulation processing and automatic palletizing production line, including an uncoiler, a leveler, a laser cutter, a synchronous inspection platform and a picking and palletizing device arranged sequentially along the sheet metal conveying direction; The discharge end of the leveling machine is equipped with a length measuring device for real-time detection of the conveying speed and length of the board. At least one tension sensor for real-time detection of sheet tension is provided between the uncoiler and the leveler, and between the leveler and the laser cutter. The processing table of the laser cutting machine is a roller conveyor table that can be driven by a servo motor; the rear of the synchronous inspection platform is equipped with an induction photoelectric switch; The material picking and stacking device is equipped with an electromagnetic chuck at its execution end. It also includes a control system, which includes: The synchronization control module is electrically connected to the length measuring device, the drive component of the leveling machine, and the servo motor of the roller conveyor table of the laser cutting machine. It is used to coordinately control the feeding speed of the leveling machine and the rolling speed of the roller conveyor table of the laser cutting machine based on the sheet material conveying speed fed back by the length measuring device, so that the two are kept synchronized. The path tracking control module is used to control the laser cutting head to accurately track and cut the dynamically conveyed sheet material; The tension control module is electrically connected to the tension sensor, the uncoiler, and the leveler. Based on the tension signal fed back by the tension sensor, it adjusts the unwinding torque of the uncoiler and the roll reduction of the leveler to stabilize the tension of the sheet between the uncoiler and the leveler within a preset range. The palletizing control module is electrically connected to the photoelectric induction switch and the material picking and palletizing device. In response to the material arrival signal of the photoelectric induction switch, it controls the material picking and palletizing device to move to the tail of the synchronous inspection platform and controls the electromagnetic chuck to be energized to pick up the cut sheet metal or parts, and then moves them to the palletizing position for palletizing.

[0007] As a preferred embodiment of the technical solution of the present invention, the length measuring device includes a fixed bracket installed at the discharge end of the leveling machine, a counter wheel that can be rolled and pressed onto the surface of the plate, and a rotary encoder coaxially connected to the counter wheel. The discharge end of the leveling machine is also equipped with a pair of clamping rollers directly driven by a servo motor, and the surface of the clamping rollers is coated with rubber.

[0008] A fixed-length measuring device consisting of a fixed bracket, a counter wheel, and a rotary encoder provides a simple, reliable, and high-precision rolling contact speed and length measurement scheme, providing accurate feedback signals for speed synchronization control.

[0009] A servo-driven, directly connected, rubber-coated feeding roller is added to the discharge end of the leveling machine. This increases friction through the rubber coating, preventing slippage and ensuring feeding accuracy. Furthermore, the direct connection to the servo motor eliminates transmission chain errors, further ensuring the processing accuracy of the follow-up cutting. As a preferred embodiment of the present invention, a transition device is provided between the laser cutting machine and the synchronous inspection platform. The transition device includes a transition bracket and a plurality of unpowered rollers mounted on the transition bracket.

[0010] The transition device installed between the laser cutting machine and the synchronous inspection platform provides a smooth and stable transition for the cut sheet material, avoiding jamming, scratches or deformation at the joint, and ensuring the continuity of material flow in the entire line.

[0011] As a preferred embodiment of the technical solution of the present invention, the synchronization control module achieves speed synchronization in the following manner: The sheet metal conveying speed is obtained in real time by the rotary encoder of the length measuring device. ; With the plate conveying speed As the target value, the rotational speed of the servo motor of the roller conveyor table of the laser cutting machine is adjusted through a PID control algorithm to increase the rolling speed of the roller conveyor table. With the speed of sheet material conveying Maintain consistency.

[0012] It was determined that the synchronous control would employ a PID control algorithm, which is a mature closed-loop control strategy characterized by fast response, high precision, and good stability. This strategy can ensure dynamic and real-time precise matching between the feeding speed and the cutting table speed.

[0013] As a preferred embodiment of the technical solution of the present invention, the synchronization control module adjusts the rolling speed of the roller conveyor table through the following steps. : The pulse frequency signal generated by the rotary encoder of the length measuring device is acquired in real time, and the pulse-to-speed conversion coefficient is determined according to the predetermined conversion coefficient. Calculate the current sheet material conveying speed. ; Calculate the conveying speed of the plate. Current rolling speed of the roller conveyor table speed error between Wherein, the current rolling speed of the roller conveyor table. The speed n is obtained by: obtaining the motor speed n fed back by the built-in encoder of the servo motor driving the roller conveyor table; according to the formula... Calculate the current scrolling speed Where D is the diameter of the drive roller of the roller conveyor table; The speed error The input is sent to the PID controller to calculate the control quantity used to adjust the servo motor of the roller conveyor table. ;

[0014] In the formula, These are the pre-tuned PID control parameters; The control quantity The driver outputs to the servo motor of the roller conveyor table, which in turn drives the servo motor to adjust its speed, thereby increasing the rolling speed. Dynamically track the conveying speed of the sheet material until the speed error is reduced Maintain within the set range.

[0015] The closed-loop control steps for speed synchronization are defined in detail, including speed acquisition, error calculation, PID adjustment and feedback update, forming a precise and reliable adaptive control system that can automatically compensate for external interference and ensure that the synchronization accuracy remains stable within the set range over a long period of time.

[0016] As a preferred embodiment of the technical solution of the present invention, the path tracking control module includes: The macroscopic synchronization unit is used to pre-plan the laser cutting path as a segmented curve parallel to the material conveying direction; during the cutting process, the movement of the laser cutting head on the segmented curve is dynamically adjusted according to the real-time displacement of the material fed back by the length measuring device, so that the movement time of the cutting head on each segment of the curve matches the time required for the material to be conveyed to that segment. The micro-correction unit is used to acquire the actual position coordinates of the laser cutting head in real time through a grating ruler; compare the actual position coordinates with the target path coordinates adjusted by the macro-synchronization unit to calculate the position deviation; based on the position deviation, drive the X / Y axis servo motors through a control algorithm to make the cutting head move precisely along the target path.

[0017] By using a macroscopic synchronization unit, the static cutting path and the dynamic material transport are coupled in time, achieving spatiotemporal synchronization and ensuring absolute macroscopic matching between the cutting action and the material position. This is the core of achieving high-quality follow-up cutting.

[0018] By using a micro-correction unit and a high-precision grating ruler for real-time position feedback and compensation, micro-path deviations caused by mechanical vibration and servo response delay are eliminated, ensuring the final cutting contour accuracy. This is especially suitable for the processing of complex and precision parts.

[0019] As a preferred embodiment of the technical solution of the present invention, a first tension sensor is installed between the uncoiler and the leveler, and a second tension sensor is installed between the leveler and the feeding roller. The tension control module stabilizes the sheet tension within a preset range through the following steps: Real-time acquisition of tension values ​​detected by the first tension sensor The tension value detected by the second tension sensor And calculate the average tension value. ; Calculate the average tension value Compared with the preset tension target value Deviation between ; The deviation Inputting the PID controller yields a dimensionless total regulation. ;

[0020] The total adjustment amount The dimensionsless adjustment amounts corresponding to the uncoiler and the leveler are obtained according to the preset ratio, namely: uncoiler adjustment amount. Leveling machine adjustment amount , ; According to the uncoiler adjustment amount Generate speed control instructions for the uncoiler; According to the adjustment amount of the leveling machine This generates a pressure adjustment command for the leveling machine; like If the tension is insufficient, then execute: According to the speed adjustment command, the unwinding speed of the uncoiler is reduced; According to the pressure adjustment command, increase the pressure of the roller group of the leveling machine; like If the tension is too high, then execute: According to the speed adjustment command, the unwinding speed of the uncoiler is increased; According to the pressure adjustment command, the pressure of the roller group of the leveling machine is reduced.

[0021] By employing dual tension sensors and calculating the average tension, the overall tension state of the sheet material can be more comprehensively reflected, avoiding the random errors of single-point measurements and resulting in more precise control. The PID-based closed-loop tension control steps are described in detail, and the adjustment is proportionally allocated to the uncoiler and leveler, achieving coordinated and precise tension adjustment with fast response, small overshoot, and effective suppression of tension fluctuations.

[0022] As a preferred embodiment of the technical solution of the present invention, the palletizing control module controls the palletizing operation through the following steps: In response to the material arrival signal emitted by the photoelectric switch at the tail of the synchronous inspection platform; control the picking and stacking device to move to directly above the tail of the synchronous inspection platform; control the electromagnetic chuck to be energized to generate magnetic force to pick up the sheet metal or parts located on the synchronous inspection platform. Control the picking and stacking device to move the picked-up sheet or part to the designated stacking position; control the electromagnetic chuck to de-energize and release the sheet or part, thus completing a single stacking action; After completing the single palletizing action, a material unloading completion signal is sent back to the synchronous control module of the laser cutting machine; subsequently, the palletizing control module is reset to standby mode, waiting to receive the next material arrival signal.

[0023] By sending a signal indicating that the material feeding is complete to downstream equipment, the laser cutting machine can safely begin the next round of processing, achieving truly uninterrupted cyclic production and maximizing equipment utilization.

[0024] As a preferred embodiment of the present invention, the control system further includes an exception handling module for executing at least one of the following protection logics: When the difference between the feeding speed of the leveling machine and the rolling speed of the roller conveyor table of the laser cutting machine exceeds a first threshold, an alarm or emergency stop is triggered. When the tension between the uncoiler and the leveler exceeds the preset range, an alarm or emergency stop is triggered. When the position deviation calculated by the micro-correction unit of the path tracking control module exceeds the second threshold, an alarm or emergency stop is triggered.

[0025] By integrating multiple safety protection logics such as speed deviation, tension over-limit, and path tracking failure, it provides comprehensive fault diagnosis and safety barriers for complex automated systems operating at high speeds, greatly reducing the risk of equipment damage and batch product scrapping, and improving the reliability and safety of the production line.

[0026] Secondly, the present invention also provides a control method for the sheet metal follow-up circulation processing and automatic palletizing production line described in the first aspect, comprising the following steps: The synchronous control process is executed to keep the feeding speed of the leveling machine synchronized with the rolling speed of the roller conveyor table of the laser cutting machine, based on the real-time feedback of the sheet material conveying speed from the fixed-length measuring device. The execution path tracking control process is used to control the laser cutting head to accurately track and cut the dynamically conveyed sheet material; The tension control process is executed to stabilize the tension of the sheet between the uncoiler and the leveler within a preset range by adjusting the unwinding torque of the uncoiler and the roll reduction of the leveler. The palletizing control process is executed in response to the material arrival signal emitted by the photoelectric switch at the tail of the synchronous inspection platform, controlling the picking and palletizing device to pick up the cut sheet metal or parts and palletize them.

[0027] As a preferred embodiment of the technical solution of the present invention, the synchronous control process specifically includes: The pulse frequency signal generated by the rotary encoder of the fixed-length measuring device is acquired in real time, and the current plate conveying speed is calculated. Using the sheet material conveying speed as the target value, the rotational speed of the servo motor of the roller conveying table of the laser cutting machine is adjusted by a PID control algorithm so that the rolling speed of the roller conveying table is consistent with the sheet material conveying speed.

[0028] As a preferred embodiment of the technical solution of the present invention, the execution path tracking control process specifically includes: The macroscopic synchronization process includes: The laser cutting path is pre-planned as a segmented curve parallel to the material conveying direction; during the cutting process, the movement of the laser cutting head on the segmented curve is dynamically adjusted according to the real-time displacement of the material fed back by the length measuring device. The micro-correction process includes: The actual position coordinates of the laser cutting head are obtained in real time by a grating ruler and compared with the target path coordinates after adjustment by the macroscopic synchronization process to calculate the position deviation; based on the position deviation, the X / Y axis servo motors are driven to make the cutting head move precisely along the target path.

[0029] As a preferred embodiment of the technical solution of the present invention, the tension control process specifically includes: The tension values ​​detected by the first tension sensor and the second tension sensor are acquired in real time, and the average tension value is calculated. Calculate the deviation between the average tension value and the preset tension target value; The deviation is input into the PID controller to obtain the total adjustment amount, and then distributed according to a preset ratio to obtain the adjustment amount for the uncoiler and the adjustment amount for the leveler; Based on the aforementioned adjustment amount, adjustment commands are generated and executed for the unwinding speed of the uncoiler and the pressing amount of the leveler roller group to eliminate the tension deviation.

[0030] As a preferred embodiment of the technical solution of the present invention, the palletizing control process specifically includes: In response to the material arrival signal, the picking and palletizing device is controlled to perform adsorption and palletizing actions; After completing a single palletizing operation, a material unloading completion signal is sent back to the laser cutting machine, and then the machine is reset to standby mode.

[0031] As a preferred embodiment of the technical solution of the present invention, it further includes an exception handling process, which executes at least one of the following protection logics: When the difference between the feeding speed of the leveling machine and the rolling speed of the roller conveyor table of the laser cutting machine exceeds the first threshold, an alarm or emergency stop is triggered. When the tension between the uncoiler and the leveler exceeds the preset range, an alarm or emergency stop is triggered. When the actual position of the laser cutting head deviates from the preset path by more than the second threshold, an alarm or emergency stop is triggered.

[0032] As a preferred embodiment of the technical solution of the present invention, the synchronous control module ensures that the feeding speed of the leveling machine and the rolling speed of the roller conveyor table of the laser cutting machine are synchronized with each other with an error of no more than 0.1 m / min.

[0033] As a preferred embodiment of the technical solution of the present invention, the tension control module adjusts the unwinding torque of the uncoiler and the roll reduction of the leveler through a closed-loop PID control algorithm, so that the tension control error is no greater than 5N.

[0034] As can be seen from the above technical solutions, this application has the following advantages: by integrating and arranging the four major functional modules of uncoiling, leveling, cutting, inspection and palletizing in a straight line, a complete fully automated production line is constructed, which improves the overall production efficiency.

[0035] By setting up a fixed-length measuring device and a synchronous control module, the feeding speed and the rolling speed of the cutting table are synchronized, laying the foundation for follow-up cutting, eliminating the waiting time of feeding-stopping-cutting in the traditional process, and improving processing efficiency.

[0036] By setting up tension sensors and tension control modules, real-time monitoring and automatic adjustment of the tension of the sheet material are achieved, effectively preventing quality problems such as loosening, wrinkling or cracking of the sheet material caused by unstable tension during high-speed continuous production, and ensuring the stability of the processing process and product quality.

[0037] By using electromagnetic chucks for unloading, the industry problem of traditional vacuum chucks leaking air and failing to reliably adsorb parts due to dense cutting paths has been overcome, achieving universal automatic unloading from whole plates to parts of any shape. Attached Figure Description

[0038] To more clearly illustrate the technical solution of this application, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a schematic diagram of the production line of the present invention.

[0040] Figure 2 This is a schematic diagram of the length-fixing device for a leveling machine.

[0041] Figure 3 This is a schematic diagram of the roller conveyor table structure of a laser cutting machine.

[0042] Figure 4 This is a schematic diagram of the transition device structure.

[0043] Figure 5 Schematic diagram of the synchronous material inspection platform.

[0044] Figure 6 This is a schematic diagram of the material picking and stacking device.

[0045] Figure 7This is a schematic diagram of the palletizing device.

[0046] Figure 8 This is a control logic block diagram in an embodiment of the present invention.

[0047] In the diagram, 1-uncoiling machine, 2-leveling machine, 3-laser cutting machine, 4-transition device, 5-synchronous inspection platform, 6-picking and stacking device, 7-fixed bracket, 8-counter wheel, 9-rotary encoder, 10-roller conveyor table, 11-support component, 12-induction photoelectric switch, 13-stacking device, 14-inspection device. Detailed Implementation

[0048] To make the purpose, features, and advantages of this application more apparent and understandable, specific embodiments and accompanying drawings will be used to clearly and completely describe the technical solution protected by this application. Obviously, the embodiments described below are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0049] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this application and in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0050] like Figure 1 As shown, this embodiment of the invention provides a sheet material follow-up circulation processing and automatic palletizing production line, including an uncoiler 1, a leveler 2, a laser cutter 3, a synchronous inspection platform 5, and a picking and palletizing device 6 arranged sequentially along the sheet material conveying direction; after uncoiling, the coil material enters the leveler through the correction device to prevent the sheet material from deviating and to ensure the accuracy of follow-up circulation processing.

[0051] The discharge end of the leveling machine 2 is equipped with a length measuring device for real-time detection of the conveying speed and length of the sheet material; the length measuring device is as follows: Figure 2 As shown, it consists of a fixed bracket 7, a counter wheel 8, and a rotary encoder 9. The length measuring device is fixed at the discharge end of the leveling machine. The counter wheel 8 presses on the leveled board. As the leveled board is conveyed forward, it drives the counter wheel 8 pressing on the board to rotate. The counter wheel 8 is directly connected to the rotary encoder 9, which in turn drives the rotary encoder to rotate. The actual conveying distance of the board is calculated by the diameter of the rubber wheel of the counter wheel 8, and the signal is transmitted to the laser cutting machine to achieve precise positioning and follow-up cyclic cutting processing.

[0052] At least one tension sensor for real-time detection of sheet tension is provided between the uncoiler 1 and the leveler 2, and between the leveler 2 and the laser cutter 3. like Figure 3 As shown, the processing table of the laser cutting machine is a roller conveyor table 10 driven by a servo motor. The host computer of the laser cutting machine receives the position signal from the length measuring device of the leveling machine. Through calculation and analysis by the host computer, the servo motor driver is matched to the same conveying speed as the material of the leveling machine, preventing scratches on the material while achieving precise feeding and ensuring the accuracy of the follow-up cyclic cutting process. The cut parts pass through the transition device 4 as shown... Figure 4 As shown, the material is conveyed to the synchronous inspection platform 5. The transition device includes a transition bracket and multiple unpowered rollers mounted on the transition bracket, providing transition support for the sheet material as it enters the synchronous inspection platform from the laser cutter. The unpowered rollers are not powered and can be matched to any conveying speed of the laser cutter.

[0053] Synchronous material inspection platform 5 Figure 5 As shown, the synchronous inspection platform 5 is equipped with a photoelectric induction switch 12 at its tail end. Unlike traditional belt conveyors, the synchronous inspection platform has a polyurethane support component 11 under the conveyor belt, which is less expensive than traditional metal support components. Furthermore, compared to traditional metal support components, the polyurethane material ensures that electromagnetic adsorption will not attract metal parts under the belt during inspection, facilitating material unloading by the inspection and palletizing device. When the sheet material is conveyed to the tail end of the synchronous inspection platform, the photoelectric induction switch 12 is triggered, sending a material arrival signal to the inspection and palletizing device, which then performs the unloading action.

[0054] Picking and stacking device 6 Figure 6As shown, it mainly consists of a palletizing device 13 and a material inspection device 14. It adopts a single-sided gantry structure for fixation, allowing for movement in different positions (front, back, up, down). Multiple electromagnetic chucks are installed at the end of the device. These chucks utilize electromagnetic principles; by energizing an internal coil, they generate magnetic force, which, through a magnetically conductive panel, tightly attracts the workpiece contacting the panel surface. Demagnetization occurs when the coil is de-energized, eliminating the magnetic force. For parts that have been cut, micro-connection is required. However, due to the dense cutting paths, traditional chucks cannot hold the parts, preventing manual unloading. Currently, manual unloading is the standard method. The electromagnetic chucks solve this problem. Furthermore, the support components under the conveyor belt of the synchronous inspection platform are made of polyurethane, avoiding the risk of accidental suction to the conveyor belt during electromagnetic adsorption of parts. When the cut parts reach the tail end of the synchronous inspection platform 5 after passing through the transition device, the photoelectric switch at the tail of the synchronous inspection platform senses the signal and transmits it to the material inspection and palletizing device 6, which then begins the material picking action. Once the material picking is completed, the picking and stacking device 6 will send a cutting signal to the laser cutting machine, and the laser cutting machine will continue to perform the follow-up cyclic cutting action.

[0055] Palletizing equipment such as Figure 7 As shown, the palletizing device buffers parts and performs palletizing and material handling. When the quantity reaches a certain level, it is removed by a forklift. The palletizing device consists of a frame, 5 side baffles, and 3 material handling devices. At the same time, the material handling devices can be adjusted forward and backward. According to the size of the parts, the material handling devices can be adjusted to the corresponding position to meet the palletizing and material handling of parts of different sizes.

[0056] It also includes a control system, which includes: The synchronization control module is electrically connected to the length measuring device, the drive component of the leveling machine 2, and the servo motor of the roller conveyor table of the laser cutting machine 3. It is used to coordinate the control of the feeding speed of the leveling machine 2 and the rolling speed of the roller conveyor table of the laser cutting machine 3 based on the plate conveying speed fed back by the length measuring device, so that the two are kept synchronized. The path tracking control module is used to control the laser cutting head to accurately track and cut the dynamically conveyed sheet material; The tension control module is electrically connected to the tension sensor, the uncoiler 1 and the leveler 2. Based on the tension signal fed back by the tension sensor, it adjusts the unwinding torque of the uncoiler 1 and the roll reduction of the leveler 2 to stabilize the tension of the sheet between the uncoiler 1 and the leveler 2 within a preset range. The palletizing control module is electrically connected to the photoelectric induction switch 12 and the material picking and palletizing device 6. In response to the material arrival signal of the photoelectric induction switch 12, it controls the material picking and palletizing device 6 to move to the tail of the synchronous inspection platform 5, and controls the electromagnetic chuck to be energized to pick up the cut sheet metal or parts, and then moves them to the palletizing position for palletizing.

[0057] The control logic of this application adopts a three-level hierarchical architecture: Sensing layer: Real-time data collection of board status and equipment operating parameters through various sensors; Decision-making level: The industrial controller processes the sensed data and calculates the target control quantity; Execution layer: Actuators such as servo motors and lasers adjust their actions according to the control input.

[0058] Combination Figures 1-7 The specific process is explained below; The encoder at the end of the feed roller's drive roller shaft is used to monitor the feeding speed; the grating rulers on the X / Y axes of the gantry platform are used to monitor the position and speed of the cutting head; tension sensors are installed on the transition rollers (tension detection rollers) between the uncoiler and the leveler, and on the transition rollers between the leveler and the feed roller, calculating the sheet tension by measuring the roller deformation; the vision positioning module further includes an industrial camera on the side of the laser cutting head, used to monitor the sheet offset on the side of the laser cutting head; the contour feature points scan the initial edge or marker points of the sheet, correcting the reference position of the feed roller and the cutting platform.

[0059] After the system is powered on, the initialization and startup process is executed first: 1. System Self-Check: The industrial controller (usually a combination of PLC and motion control card) checks the communication status of each servo drive and sensor (including encoder, linear scale, tension sensor). After confirming that there are no faults, it controls the cutting head to return to the mechanical zero point and the feeding roller to return to its original position.

[0060] 2. Pre-tension setting: Based on the material and thickness of the sheet material being processed, preset the initial tension. By controlling the magnetic powder brake of the uncoiler and the roller depressor of the leveler, the sheet material is pre-tensioned to prevent loosening during startup.

[0061] 3. Speed ​​pre-synchronization and accelerated climb: The feeding roller and laser cutting head start at a low speed (e.g., 2 m / min). The controller calculates the initial synchronization error between the feeding speed and the cutting head moving speed through feedback from the encoder and grating ruler.

[0062] The servo motor speed is dynamically adjusted by using a PID control algorithm to reduce the synchronization error to an allowable range (e.g., ≤0.1m / min).

[0063] Subsequently, the system smoothly and synchronously increases the feeding and cutting speeds to the target processing speed (e.g., 10 m / min) at a preset acceleration (e.g., 0.5 m / s²). During this acceleration process, the tension control system intervenes in real time. If excessive tension is detected, the unwinding speed of the uncoiler is reduced; if insufficient tension is detected, the pressure of the leveler is increased to maintain tension stability.

[0064] During the continuous conveying and cutting of the sheet metal, the system enters steady-state operation, and the core control modules work in parallel: (1) Synchronous feeding and cutting control, which is achieved through a synchronous control module in this embodiment of the invention; Objective: To ensure real-time synchronization between the sheet metal conveying speed and the movement speed of the laser cutting head in the sheet metal conveying direction. Speed ​​synchronization is achieved through the following methods: The sheet metal conveying speed is acquired in real time by the rotary encoder 9 of the length measuring device. ; With the plate conveying speed As the target value, the rotational speed of the servo motor of the roller conveyor table of the laser cutting machine 3 is adjusted by a PID control algorithm to increase the rolling speed of the roller conveyor table. With the speed of sheet material conveying Maintain consistency.

[0065] The synchronization control module adjusts the rolling speed of the roller conveyor table through the following steps. : The pulse frequency signal generated by the rotary encoder 9 of the length measuring device is acquired in real time, and the pulse-to-speed conversion coefficient is determined according to the predetermined conversion coefficient. Calculate the current sheet material conveying speed. ; Calculate the conveying speed of the plate. Current rolling speed of the roller conveyor table speed error between Wherein, the current rolling speed of the roller conveyor table. The speed n is obtained by: obtaining the motor speed n fed back by the built-in encoder of the servo motor driving the roller conveyor table; according to the formula... Calculate the current scrolling speed Where D is the diameter of the drive roller of the roller conveyor table; The speed error The input is sent to the PID controller to calculate the control quantity used to adjust the servo motor of the roller conveyor table. ;

[0066] In the formula, These are the pre-tuned PID control parameters; The control quantity The driver outputs to the servo motor of the roller conveyor table, which in turn drives the servo motor to adjust its speed, thereby increasing the rolling speed. Dynamically track the conveying speed of the sheet material until the speed error is reduced Maintain within the set range. Control the synchronization error within the process requirements (e.g., ≤0.1 m / min).

[0067] (2) Dynamic tracking control of the cutting path, which is implemented through a path tracking control module in this embodiment of the invention; Objective: To ensure that the cutting head always accurately follows the preset cutting path while maintaining speed synchronization.

[0068] The path tracking control module includes: The macroscopic synchronization unit is used to pre-plan the laser cutting path as a segmented curve parallel to the material conveying direction; during the cutting process, the movement of the laser cutting head on the segmented curve is dynamically adjusted according to the real-time displacement of the material fed back by the length measuring device, so that the movement time of the cutting head on each segment of the curve matches the time required for the material to be conveyed to that segment. The micro-correction unit is used to acquire the actual position coordinates of the laser cutting head in real time through a grating ruler; compare the actual position coordinates with the target path coordinates adjusted by the macro-synchronization unit to calculate the position deviation; based on the position deviation, drive the X / Y axis servo motors through a control algorithm to make the cutting head move precisely along the target path.

[0069] The path tracking control module receives discrete path points generated by CAM software. First, it uses a spline interpolation algorithm to convert these points into a continuous and smooth motion trajectory. Second, it acquires the actual position (x, y) of the cutting head in real time using a grating ruler and compares it with the target path points to calculate the position deviation (Δx, Δy). Finally, it employs a combined control method of feedforward (predicting path curvature to compensate for mechanical delay) and feedback (PID adjustment) to drive the X / Y axis servo motors, eliminating position deviations and achieving high-precision (e.g., ±0.2mm) path tracking.

[0070] (3) Adaptive tension control is achieved through a tension control module; Objective: To maintain constant tension in the sheet material between the uncoiling and leveling processes, preventing the sheet material from loosening, wrinkling, or being overstretched.

[0071] Specifically, tension sensors installed between the uncoiler and the leveler, and between the leveler and the feed rollers, monitor the tension value in real time, calculate its average value, and compare it with the set tension value to obtain the tension deviation. Based on the sign and magnitude of the deviation, the controller outputs commands to adjust the unwinding speed of the uncoiler (via a frequency converter) and / or the pressing amount of the leveler roller group (via a hydraulic servo valve), forming a closed-loop control to stabilize the tension within a preset range (error ≤ 5N).

[0072] Specifically, a first tension sensor is installed between the uncoiler 1 and the leveler 2, and a second tension sensor is installed between the leveler 2 and the feeding roller; The tension control module stabilizes the sheet tension within a preset range through the following steps: Real-time acquisition of tension values ​​detected by the first tension sensor The tension value detected by the second tension sensor And calculate the average tension value. ; Calculate the average tension value Compared with the preset tension target value Deviation between ; The deviation Inputting the PID controller yields a dimensionless total regulation. ;

[0073] The total adjustment amount According to the preset ratio, the dimensionless adjustment amounts corresponding to uncoiler 1 and leveler 2 are obtained respectively, namely: uncoiler adjustment amount. Leveling machine adjustment amount , ; According to the uncoiler adjustment amount Generate speed control instructions for uncoiler 1; According to the adjustment amount of the leveling machine Generate the pressure reduction command for leveling machine 2; like If the tension is insufficient, then execute: According to the speed adjustment command, the unwinding speed of the uncoiler 1 is reduced; According to the pressure adjustment command, the pressure of the roller group of the leveling machine 2 is increased; like If the tension is too high, then execute: According to the speed adjustment command, the unwinding speed of the uncoiler 1 is increased; According to the pressure adjustment command, the pressure of the roller group of the leveling machine 2 is reduced.

[0074] (4) Finishing and palletizing control, which is implemented by a palletizing control module in this embodiment of the invention; When the system detects that the material is about to be cut, it controls the feeding roller and the cutting head to decelerate smoothly at a preset deceleration. After the cutting head completes the final cut, it performs a retraction action (such as reducing laser power) and quickly returns to the standby position. Specifically, the palletizing control module responds to the material arrival signal emitted by the photoelectric switch 12 at the tail of the synchronous inspection platform 5; controls the picking and palletizing device 6 to move to directly above the tail of the synchronous inspection platform 5; controls the electromagnetic chuck to be energized to generate magnetic force to pick up the material or part located on the synchronous inspection platform 5; controls the picking and palletizing device 6 to carry the picked-up material or part to the designated pallet position; controls the electromagnetic chuck to be de-energized to release the material or part, completing a single palletizing action; after completing the single palletizing action, it sends a material unloading completion signal back to the synchronous control module of the laser cutting machine 3; subsequently, the palletizing control module resets to the standby state, waiting to receive the next material arrival signal.

[0075] In other words, the cut parts are transported to the synchronous inspection platform via a transition device. When a part reaches the end of the platform and triggers a photoelectric switch, the palletizing control module responds to this signal and controls the picking and palletizing device to move above the platform. The electromagnetic chuck at the end of the device is energized, picks up the part, moves it to the palletizing area, and releases it when the power is turned off, completing one palletizing operation. After palletizing is completed, the system sends a signal to the laser cutting machine, which can then start the next processing cycle.

[0076] The system integrates multiple security protection mechanisms, and the control system also includes an exception handling module for executing at least one of the following protection logics: Speed ​​error protection: When the synchronization error between the feeding and cutting speeds exceeds the safety threshold, the system will alarm and trigger an emergency stop.

[0077] Tension over-limit protection: When the real-time tension exceeds the sheet's tolerance range or is too low, the system immediately takes protective measures, such as stopping unwinding.

[0078] Path tracking failure protection: When the deviation between the actual position of the cutting head and the preset path continues to exceed the tolerance, the system will pause cutting and issue an alarm.

[0079] like Figure 8 As shown, this embodiment of the invention also provides a control method for the sheet metal follow-up circulation processing and automatic palletizing production line described in the above embodiments, comprising the following steps: The synchronous control process is executed to keep the feeding speed of the leveling machine synchronized with the rolling speed of the roller conveyor table of the laser cutting machine, based on the real-time feedback of the sheet material conveying speed from the fixed-length measuring device. The execution path tracking control process is used to control the laser cutting head to accurately track and cut the dynamically conveyed sheet material; The tension control process is executed to stabilize the tension of the sheet between the uncoiler and the leveler within a preset range by adjusting the unwinding torque of the uncoiler and the roll reduction of the leveler. The palletizing control process is executed in response to the material arrival signal emitted by the photoelectric switch at the tail of the synchronous inspection platform, controlling the picking and palletizing device to pick up the cut sheet metal or parts and palletize them.

[0080] In some embodiments, performing the synchronization control process specifically includes: The pulse frequency signal generated by the rotary encoder of the fixed-length measuring device is acquired in real time, and the current plate conveying speed is calculated. Using the sheet material conveying speed as the target value, the rotational speed of the servo motor of the roller conveying table of the laser cutting machine is adjusted by a PID control algorithm so that the rolling speed of the roller conveying table is consistent with the sheet material conveying speed.

[0081] In some embodiments, the path tracing control process specifically includes: The macroscopic synchronization process includes: The laser cutting path is pre-planned as a segmented curve parallel to the material conveying direction; during the cutting process, the movement of the laser cutting head on the segmented curve is dynamically adjusted according to the real-time displacement of the material fed back by the length measuring device. The micro-correction process includes: The actual position coordinates of the laser cutting head are obtained in real time by a grating ruler and compared with the target path coordinates after adjustment by the macroscopic synchronization process to calculate the position deviation; based on the position deviation, the X / Y axis servo motors are driven to make the cutting head move precisely along the target path.

[0082] In some embodiments, the tension control process specifically includes: The tension values ​​detected by the first tension sensor and the second tension sensor are acquired in real time, and the average tension value is calculated. Calculate the deviation between the average tension value and the preset tension target value; The deviation is input into the PID controller to obtain the total adjustment amount, and then distributed according to a preset ratio to obtain the adjustment amount for the uncoiler and the adjustment amount for the leveler; Based on the aforementioned adjustment amount, adjustment commands are generated and executed for the unwinding speed of the uncoiler and the pressing amount of the leveler roller group to eliminate the tension deviation.

[0083] In some embodiments, the palletizing control process specifically includes: In response to the material arrival signal, the picking and palletizing device is controlled to perform adsorption and palletizing actions; After completing a single palletizing operation, a material unloading completion signal is sent back to the laser cutting machine, and then the machine is reset to standby mode.

[0084] In some embodiments, an exception handling process is also included, which executes at least one of the following protection logic: When the difference between the feeding speed of the leveling machine and the rolling speed of the roller conveyor table of the laser cutting machine exceeds the first threshold, an alarm or emergency stop is triggered. When the tension between the uncoiler and the leveler exceeds the preset range, an alarm or emergency stop is triggered. When the actual position of the laser cutting head deviates from the preset path by more than the second threshold, an alarm or emergency stop is triggered.

[0085] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A sheet metal follow-up circulation processing and automatic palletizing production line, characterized in that, The assembly includes an uncoiler (1), a leveler (2), a laser cutter (3), a synchronous inspection platform (5), and a picking and stacking device (6) arranged sequentially along the conveying direction of the sheet metal. The discharge end of the leveler (2) is equipped with a length measuring device for real-time detection of the conveying speed and length of the sheet metal. At least one tension sensor for real-time detection of the tension of the sheet metal is provided between the uncoiler (1) and the leveler (2), and between the leveler (2) and the laser cutter (3). The processing table of the laser cutter (3) is a roller conveying table (10) driven by a servo motor. The tail of the synchronous inspection platform (5) is equipped with an induction photoelectric switch (12). The execution end of the picking and stacking device (6) is equipped with an electromagnetic chuck. It also includes a control system, which includes: The synchronization control module is electrically connected to the fixed length measuring device, the driving component of the leveling machine (2) and the servo motor of the roller conveying table of the laser cutting machine (3). It is used to coordinate the control of the feeding speed of the leveling machine (2) and the rolling speed of the roller conveying table (10) of the laser cutting machine (3) based on the plate conveying speed fed back by the fixed length measuring device, so that the two are kept synchronized. The path tracking control module is used to control the laser cutting head to accurately track and cut the dynamically conveyed sheet material; The tension control module is electrically connected to the tension sensor, the uncoiler (1) and the leveler (2) to stabilize the tension of the sheet within a preset range by adjusting the unwinding torque of the uncoiler (1) and the roll pressing amount of the leveler (2) based on the tension signal fed back by the tension sensor. The palletizing control module is electrically connected to the photoelectric induction switch (12) and the picking and palletizing device (6). In response to the material arrival signal of the photoelectric induction switch (12), the module controls the picking and palletizing device (6) to move to the tail of the synchronous inspection platform (5) and controls the electromagnetic chuck to be energized to pick up the cut plate or parts, and then moves to the pallet position for palletizing.

2. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 1, characterized in that, The fixed-length measuring device includes a fixed bracket (7), a counter wheel (8), and a rotary encoder (9); The fixed bracket (7) is installed at the discharge end of the leveling machine (2); The counter wheel (8) is rotatably mounted on the fixed bracket (7), and the rim of the counter wheel (8) is configured to be rolled and pressed onto the surface of the leveled plate. The rotary encoder (9) is coaxially connected to the counter wheel (8) and is used to detect the rotation angle of the counter wheel (8); The discharge end of the leveling machine (2) is also equipped with a pair of clamping rollers driven directly by a servo motor, and the surface of the clamping rollers is coated with rubber.

3. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 2, characterized in that, A transition device (4) is provided between the laser cutting machine (3) and the synchronous inspection platform (5). The transition device (4) includes a transition bracket and a plurality of unpowered rollers mounted on the transition bracket.

4. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 3, characterized in that, The synchronization control module achieves speed synchronization in the following way: The sheet metal conveying speed is obtained in real time by the rotary encoder (9) of the length measuring device. ; With the plate conveying speed As the target value, the rotational speed of the servo motor of the roller conveyor table of the laser cutting machine (3) is adjusted by the PID control algorithm to increase the rolling speed of the roller conveyor table (10). With the speed of sheet material conveying Maintain consistency.

5. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 4, characterized in that, The synchronization control module adjusts the rolling speed of the roller conveyor table (10) through the following steps. : The pulse frequency signal generated by the rotary encoder (9) of the length measuring device is acquired in real time, and the pulse-speed conversion coefficient is determined according to the predetermined pulse-speed conversion coefficient. Calculate the current sheet material conveying speed. ; Calculate the conveying speed of the sheet material Current rolling speed of the roller conveyor table (10) speed error between Among them, the current rolling speed of the roller conveyor table (10) The speed n is obtained by: obtaining the motor speed n fed back by the built-in encoder of the servo motor driving the roller conveyor table; according to the formula... Calculate the current scrolling speed Where D is the diameter of the drive roller of the roller conveyor table; speed error The input is fed into the PID controller, which calculates the control quantity used to adjust the servo motor of the roller conveyor table. ; In the formula, These are the pre-tuned PID control parameters; The control quantity The driver outputs to the servo motor of the roller conveyor table, which in turn drives the servo motor to adjust its speed, thereby increasing the rolling speed. Dynamically track the conveying speed of the sheet material until the speed error is reduced Maintain within the set range.

6. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 5, characterized in that, The X-axis and Y-axis motion platforms of the laser cutting machine are equipped with grating rulers connected to the control system; the path tracking control module includes: The macroscopic synchronization unit is used to pre-plan the laser cutting path as a segmented curve parallel to the material conveying direction; during the cutting process, the movement of the laser cutting head on the segmented curve is dynamically adjusted according to the real-time displacement of the material fed back by the length measuring device, so that the movement time of the cutting head on each segment of the curve matches the time required for the material to be conveyed to that segment. The micro-correction unit is used to acquire the actual position coordinates of the laser cutting head in real time through a grating ruler; compare the actual position coordinates with the target path coordinates adjusted by the macro-synchronization unit to calculate the position deviation; based on the position deviation, drive the X / Y axis servo motors through a control algorithm to make the cutting head move precisely along the target path.

7. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 6, characterized in that, A first tension sensor is installed between the uncoiler (1) and the leveler (2), and a second tension sensor is installed between the leveler (2) and the feed roller; The tension control module stabilizes the sheet tension within a preset range through the following steps: Real-time acquisition of tension values ​​detected by the first tension sensor The tension value detected by the second tension sensor ; And calculate the average tension value ; Calculate the average tension value Compared with the preset tension target value Deviation between ; The deviation Inputting the PID controller yields a dimensionless total regulation. ; The total adjustment amount According to the preset ratio, the dimensionless adjustment amounts corresponding to the uncoiler (1) and the leveler (2) are obtained respectively, namely: uncoiler adjustment amount Leveling machine adjustment amount , ; According to the uncoiler adjustment amount , generate speed control instructions for the uncoiler (1); According to the adjustment amount of the leveling machine , generate the pressure adjustment command for the leveling machine (2); like If the tension is insufficient, then execute: According to the speed adjustment command, the unwinding speed of the uncoiler (1) is reduced; According to the pressure adjustment command, increase the pressure of the roller group of the leveling machine (2); like If the tension is too high, then execute: According to the speed adjustment command, the unwinding speed of the uncoiler (1) is increased; According to the pressure adjustment command, the amount of pressure of the roller group of the leveling machine (2) is reduced.

8. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 6, characterized in that, The palletizing control module controls the palletizing operation through the following steps: In response to the material arrival signal emitted by the photoelectric switch (12) at the tail of the synchronous inspection platform (5), the picking and stacking device (6) is controlled to move to directly above the tail of the synchronous inspection platform (5); the electromagnetic chuck is controlled to be energized to generate magnetic force to pick up the plate or parts located on the synchronous inspection platform (5); Control the picking and stacking device (6) to move the picked-up sheet or part to the designated stacking position; control the electromagnetic chuck to de-energize and release the sheet or part, thus completing a single stacking action; After completing the single palletizing action, a material unloading completion signal is fed back to the synchronous control module of the laser cutting machine (3); subsequently, the palletizing control module is reset to standby state, waiting to receive the next material arrival signal.

9. The sheet metal follow-up circulation processing and automatic palletizing production line according to claim 8, characterized in that, The control system further includes an exception handling module for executing at least one of the following protection logics: When the difference between the feeding speed of the leveling machine (2) and the rolling speed of the roller conveyor table (10) of the laser cutting machine (3) exceeds the first threshold, an alarm or emergency stop is triggered. When the tension between the uncoiler (1) and the leveler (2) exceeds the preset range, an alarm or emergency stop is triggered; When the position deviation calculated by the micro-correction unit of the path tracking control module exceeds the second threshold, an alarm or emergency stop is triggered.

10. A control method for a sheet metal follow-up cyclic processing and automatic palletizing production line according to any one of claims 1-9, characterized in that, Includes the following steps: The synchronous control process is executed so that the feeding speed of the leveling machine (2) is synchronized with the rolling speed of the roller conveying table (10) of the laser cutting machine (3) based on the real-time feedback of the plate conveying speed of the fixed length measuring device. The execution path tracking control process is used to control the laser cutting head to accurately track and cut the dynamically conveyed sheet material; The tension control process is performed to stabilize the tension of the sheet between the uncoiler (1) and the leveler (2) within a preset range by adjusting the unwinding torque of the uncoiler (1) and the roll pressing amount of the leveler (2); The palletizing control process is executed in response to the material arrival signal emitted by the photoelectric switch (12) at the tail of the synchronous inspection platform (5), and the picking and palletizing device (6) is controlled to pick up the cut plates or parts and palletize them.

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