Stamping inductive control method and system for caster support in and out of material

Abstract

The application provides a castor support feeding and discharging stamping induction control method and system, relates to the technical field of control systems, and has the technical scheme as follows: feeding signals, pushing signals, discharging signals, reset signals, and actual time corresponding to the above signals are acquired in real time, the feeding signals are generated by feeding actions of a material belt, the pushing signals are generated by pushing actions of two air cylinders, the discharging signals are generated by discharging actions of the two air cylinders and detection actions of products passing through a discharging port, and the reset signals are generated by return reset actions of the two air cylinders; feeding signals, pushing signals, discharging signals, reset signals, and actual time in a same stamping period are detected and judged in real time according to the sequence of the feeding, pushing, discharging, and resetting processes. The castor support feeding and discharging stamping induction control method and system have the advantages of orderly detection, differentiated abnormal response, and full-process fault tracing.

Description

Technical Field

[0001] This application relates to the field of control system technology, and more specifically, to a method and system for induction control of material feeding and discharging of caster brackets. Background Technology

[0002] In the stamping production of caster brackets, automated control of the feeding and unloading processes is crucial for ensuring production efficiency, product qualification rate, and equipment safety. Currently, existing caster bracket stamping production lines use belt feeding and two cylinders synchronously driven to achieve pushing, unloading, and resetting actions, working in conjunction with a punch press to complete the stamping process. However, these existing caster bracket stamping production lines still have many problems in terms of feeding and unloading stamping sensing control:

[0003] 1. Chaotic detection logic: Existing technologies mostly adopt multi-signal parallel detection or disordered detection mode, without combining the feeding, pushing, discharging and resetting stages of the stamping process for targeted detection. This is prone to cross-interference of signals in multiple stages, leading to abnormal misjudgment or missed judgment, which in turn causes product scrapping or equipment failure.

[0004] 2. Insufficient Abnormal Response Methods: Faced with abnormalities of varying stages and severity, a "one-size-fits-all" shutdown strategy is commonly adopted, failing to differentiate the scope and extent of the impact. For example, minor deviations during the reset phase and severe offsets during the feeding phase both trigger immediate shutdowns, potentially leading to the scrapping of qualified products in the current cycle or reducing production efficiency due to excessive downtime.

[0005] 3. Lack of fault tracing capabilities: Most solutions can only achieve abnormal shutdown, lacking the functions of collecting and storing data during abnormal phases, locating the source of faults, and generating diagnostic reports. After shutdown, manual troubleshooting is required, which takes a long time and seriously affects production continuity.

[0006] There is currently no effective technical solution to the above problems. Summary of the Invention

[0007] The purpose of this application is to provide a method and system for controlling the feeding and discharging of caster brackets by induction, which has the advantages of orderly detection, differentiated abnormal response and full-process fault tracing.

[0008] In a first aspect, this application provides a method for controlling the feeding and discharging of a caster bracket using a stamping induction sensor, the method comprising the following steps:

[0009] The feeding signal, pushing signal, discharging signal, and reset signal, as well as the actual time taken for each of the above signals, are acquired in real time. The feeding signal is generated by the feeding action of the material belt, the pushing signal is generated by the pushing action of the two cylinders, the discharging signal is generated by the discharging action of the two cylinders and the detection action of the product passing through the discharge port, and the reset signal is generated by the return reset action of the two cylinders.

[0010] According to the process sequence of feeding, pushing, discharging, and resetting, the system detects and judges in real time whether any abnormalities occur in the feeding signal, pushing signal, discharging signal, resetting signal, and actual time usage within the same stamping cycle.

[0011] When any of the above signals is missing, abnormal, or the actual time exceeds the standard timing interval, the corresponding warning is triggered or the punch press is stopped and the cylinder action is locked. The corresponding warnings include feeding warning, pushing warning, discharging warning, and reset warning.

[0012] Furthermore, in this application, when any of the above signals is missing, abnormal, or the actual time exceeds the standard timing interval, the steps of triggering the corresponding warning or controlling the punch press to stop and locking the cylinder action also include:

[0013] Real-time acquisition of edge position signals and belt tension signals of the material belt, both of which are feeding signals;

[0014] Determine whether the material strip offset corresponding to the edge position signal exceeds the preset offset threshold, and at the same time determine whether the tension value corresponding to the material strip tension signal exceeds the preset tension range;

[0015] When the material belt offset intermittently exceeds the preset offset threshold, or the tension value intermittently exceeds the preset tension range, a feeding warning is triggered. The feeding warning includes generating voice and text prompts, displaying abnormal data of material belt offset and tension value on the local display unit, and controlling the feeding mechanism to reduce the feeding speed and shorten the acquisition interval between the edge position signal and the material belt tension signal.

[0016] When the material strip offset exceeds the preset offset threshold for three consecutive stamping cycles, or the tension value exceeds the preset tension range for three consecutive stamping cycles and the fluctuation range continues to increase, the press will be stopped immediately and the material strip and cylinder feeding action will be locked.

[0017] Collect and store the timing data of belt offset, tension fluctuation data and belt operation parameters during the abnormal feeding stage;

[0018] Based on the timing data of belt offset, tension fluctuation data and belt operating parameters, the cause of belt offset or tension abnormality is located.

[0019] Generate a material feeding fault diagnosis report that includes fault type and abnormal feeding signal, and display it visually through the local display unit.

[0020] Furthermore, in this application, when any of the above signals is missing, abnormal, or the actual time exceeds the standard timing interval, the steps of triggering the corresponding warning or controlling the punch press to stop and locking the cylinder action also include:

[0021] Real-time acquisition of the first stroke information and the second stroke information generated by the two cylinders during the pushing process, both of which are pushing signals;

[0022] Real-time calculation of the synchronization rate between the first and second travel information and analysis of whether it meets the preset synchronization rate;

[0023] When the synchronization rate is less than the preset synchronization rate, immediately control the punch press to stop and lock the cylinder action;

[0024] When the synchronization rate is greater than or equal to the preset synchronization rate, analyze the trend of the synchronization rate.

[0025] Furthermore, in this application, when the synchronization rate is greater than or equal to a preset synchronization rate, the step of analyzing the trend of the synchronization rate also includes:

[0026] When the synchronization rate decreases intermittently, a push warning is triggered. The push warning includes generating voice and text prompts and displaying them in a pop-up window on the local display unit, recording the time node of each intermittent decrease and the corresponding synchronization rate value, and controlling two cylinders to reduce the push speed to improve push stability, shorten the interval of stroke information collection in the subsequent push process, and improve the sensitivity of monitoring changes in synchronization rate.

[0027] When the synchronization rate decreases continuously, immediately stop the punch press and lock the cylinder action.

[0028] Furthermore, in this application, the step of immediately stopping the punch press and locking the cylinder action when the synchronization rate continuously decreases further includes:

[0029] Real-time acquisition and storage of real-time stroke data, material pushing driving force data and synchronization rate change data of the two cylinders during the continuous reduction phase of synchronization rate, recording the time point when the synchronization rate first falls below the preset synchronization rate, the duration of continuous reduction and the final synchronization rate value.

[0030] Based on the stored stroke data, pusher driving force data, and synchronization rate change data, the target cylinder with stroke lag or abnormal pusher driving force fluctuations in the two cylinders is analyzed to locate the source of the fault where the synchronization rate continuously decreases.

[0031] Generate a feeding fault diagnosis report that includes fault type, fault source, fault timing data and abnormal feeding signal, and display it visually through the local display unit.

[0032] Furthermore, in this application, when any of the above signals is missing, abnormal, or the actual time exceeds the standard timing interval, the steps of triggering the corresponding warning or controlling the punch press to stop and locking the cylinder action also include:

[0033] The light-blocking duration and light-blocking intensity of the product passing through the discharge port are collected in real time. Both the light-blocking duration and the light-blocking intensity are discharge signals.

[0034] Determine whether the shading time is within the preset discharge time range, and at the same time determine whether the shading intensity reaches the preset shading threshold.

[0035] When the duration of light blocking at any discharge port exceeds the preset discharge duration range, or the duration of light blocking intensity does not reach the preset light blocking threshold, a discharge warning is triggered. The discharge warning includes generating voice and text prompts, displaying the corresponding discharge port number in a pop-up window on the local display unit, recording the timing data of each abnormality, and controlling and adjusting the discharge speed of the corresponding side cylinder to improve the stability of the discharge push.

[0036] If no valid discharge signal is collected from any discharge port for two consecutive stamping cycles, or if the shading time exceeds the preset discharge time range for two consecutive cycles and there is no recovery trend, the press is immediately stopped and the cylinder discharge action is locked. The valid discharge signal is a detection signal in which the shading time is within the preset discharge time range and the shading intensity reaches the preset shading threshold.

[0037] Collect and store data on the duration of shading, the driving force of cylinder discharge, and the working condition image data of the discharge port during the abnormal discharge stage;

[0038] Based on the data of shading duration, cylinder discharge driving force, and discharge port working condition image data, the source of the product jamming or insufficient cylinder discharge power can be located.

[0039] Generate a discharge fault diagnosis report that includes the fault type, abnormal discharge signal and corresponding cylinder number, and simultaneously display the fault location diagram on the local display unit.

[0040] Furthermore, in this application, when any of the above signals is missing, abnormal, or the actual time exceeds the standard timing interval, the steps of triggering the corresponding warning or controlling the punch press to stop and locking the cylinder action also include:

[0041] The first return information and the second return information generated by the two cylinders during the reset process are collected in real time. Both the first return information and the second return information are reset signals.

[0042] Real-time calculation of the return deviation between the first and second return information and analysis of whether it exceeds the preset return deviation;

[0043] When the return deviation is greater than or equal to the preset return deviation, in order to avoid scrapping the products in the current stamping cycle and reduce production losses, the press is controlled to decelerate and stop after the current stamping cycle is completed, while the cylinder reset action is locked.

[0044] When the retrace deviation is less than the preset retrace deviation, analyze the trend of the retrace deviation.

[0045] Furthermore, in this application, the step of analyzing the trend of retrace deviation when the retrace deviation is less than the preset deviation further includes:

[0046] When the return deviation shows an intermittent increasing trend, a reset warning is triggered. The reset warning includes generating text prompt information and displaying it in a pop-up window on the local display unit, recording the time node of each intermittent increase and the corresponding deviation value, and controlling the punch press to maintain the current running speed and shorten the interval of subsequent stamping cycles to increase the monitoring frequency of return deviation.

[0047] When the return deviation shows a continuous increasing trend, immediately control the punch press to stop and lock the cylinder reset action.

[0048] Furthermore, in this application, when the return deviation shows a continuous increasing trend, the step of controlling the punch press to stop immediately and locking the cylinder reset action also includes:

[0049] Real-time acquisition and storage of return speed data, return driving force fluctuation data, and return deviation change data of two cylinders during the continuous increase of return deviation;

[0050] Based on return speed data, return driving force fluctuation data, and return deviation change data, the target cylinder with abnormal stroke growth or unstable return driving force in the two cylinders is analyzed to locate the fault source of continuous increase in return deviation.

[0051] Generate a reset fault diagnosis report that includes fault type, fault source, fault timing data and fault reset signal, and display it visually through the local display unit.

[0052] Secondly, this application also provides a caster bracket feeding and discharging stamping induction control system, the system comprising:

[0053] The first acquisition module is used to acquire in real time the feeding signal, pushing signal, discharging signal, reset signal and the actual time corresponding to each of the above signals. The feeding signal is generated by the feeding action of the material belt and the two cylinders. The discharging signal is generated by the discharging action of the two cylinders and the detection action of the product passing through the discharge port. The reset signal is generated by the return reset action of the two cylinders.

[0054] The first control module is used to detect and determine in real time whether the feeding signal, discharging signal, reset signal and actual time used in the same stamping cycle are abnormal, according to the order of feeding, pushing, discharging and resetting.

[0055] The second control module is used to trigger a corresponding warning or control the punch press to stop and lock the cylinder action when any of the above signals are missing, abnormal or the actual time exceeds the standard timing interval. The corresponding warnings include feeding warning, pushing warning, discharging warning and reset warning.

[0056] Other features and advantages of this application will be set forth in the following description and will be apparent in part from the description or may be learned by practicing embodiments of this application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0057] Beneficial effects:

[0058] 1. Achieve closed-loop control of the entire stamping process: covering the four core processes of feeding, pushing, discharging, and resetting, and forming a complete control chain of "signal acquisition, anomaly judgment, response and handling, and fault tracing" through the logic of full-process signal acquisition, process-sequence detection, and anomaly graded response, so as to avoid the spread of anomalies in a single process from affecting the overall production rhythm.

[0059] 2. Establish a graded response mechanism to balance production continuity and risk control: trigger early warnings and link parameter adjustments (such as speed reduction and shortening of data acquisition intervals) for intermittent anomalies in each process (such as material belt deviation exceeding the standard intermittently or synchronization rate decreasing intermittently); trigger shutdown and locking actions for continuous anomalies (such as exceeding the standard for multiple consecutive cycles or deviation increasing continuously). This reduces unnecessary shutdowns and can stop losses in time, avoiding the scrapping of batch products or equipment damage.

[0060] 3. Improve the accuracy of anomaly detection and reduce subjective judgment errors: Introduce quantitative judgment benchmarks such as preset offset threshold, preset tension range, and preset synchronization rate to transform abstract motion anomalies into comparable numerical indicators, ensuring that the anomaly detection standards of each process are consistent and the judgment is accurate, thus guaranteeing the stamping and forming accuracy of caster brackets.

[0061] 4. Optimize fault tracing efficiency and shorten maintenance downtime: After abnormal shutdown of each process, core operating data is collected synchronously to accurately locate the source of the fault (such as the target cylinder or the product jamming position) and generate a visual diagnostic report, reducing the difficulty of fault diagnosis, shortening maintenance time and improving equipment uptime.

[0062] 5. Reduce production losses and improve economic efficiency: The reset process adopts a flexible control strategy of "stopping the machine after completing the current stamping cycle" to avoid scrapping products in the current cycle; the full-process early warning mechanism intervenes in potential anomalies in advance to further reduce production losses caused by failures. Attached Figure Description

[0063] Figure 1 A flowchart of a caster bracket feeding and discharging stamping induction control method provided in an embodiment of this application;

[0064] Figure 2 This is a schematic diagram of the first structure of the caster bracket feeding and discharging stamping induction control system provided in the embodiments of this application.

[0065] Labeling explanation: 201, First acquisition module; 202, First control module; 203, Second control module. Detailed Implementation

[0066] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, and not all embodiments. The components of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0067] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, terms such as "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0068] The following discloses and provides many different implementation methods or examples to achieve the purpose of the present invention and to solve the problems existing in the prior art.

[0069] Please refer to Figure 1 As shown in the figure, this application provides a method for controlling the feeding and discharging of a caster bracket using a stamping induction sensor. The method includes the following steps:

[0070] S1. Real-time acquisition of feeding signal, pushing signal, discharging signal, reset signal and the actual time corresponding to each of the above signals. The feeding signal is generated by the feeding action of the material belt, the pushing signal is generated by the pushing action of the two cylinders, the discharging signal is generated by the discharging action of the two cylinders and the detection action of the product passing through the discharge port, and the reset signal is generated by the return reset action of the two cylinders.

[0071] S2. Real-time detection and judgment of the feeding signal, pushing signal, discharging signal, reset signal and actual time within the same stamping cycle according to the process sequence of feeding, pushing, discharging and reset.

[0072] S3. When any of the above signals is missing, abnormal, or the actual time exceeds the standard timing interval, the corresponding warning is triggered or the punch press is stopped and the cylinder action is locked. The corresponding warnings include feeding warning, pushing warning, discharging warning, and reset warning.

[0073] In step S1, the signal acquisition basis of the scheme is first clarified by defining four core signals to be acquired: feeding, pushing, discharging, and resetting. The actual time taken for each of these signals is used as an auxiliary parameter to provide data sources for subsequent anomaly detection. Secondly, the generation scenario or subject of each type of signal is clarified, such as distinguishing that the feeding signal comes from the material belt movement, and the pushing, discharging, and resetting signals come from the cylinder movement. This ensures that subsequent detection has clear objects and data support, and guarantees the relevance and accuracy of the data.

[0074] In step S2, the detection logic of the solution is firstly defined as detecting according to the stamping process sequence to avoid cross-interference of signals from multiple stages and to solve the problem of misjudgment or omission caused by disordered detection in existing technologies. Secondly, the detection range is limited to the same stamping cycle to ensure the timeliness and relevance of the detection. Stamping production is cyclical, and signal abnormalities within a single cycle directly affect the quality of a single batch of products. Finally, the detection purpose is defined as determining whether signals are missing or abnormal and whether the actual time taken exceeds the standard time interval, providing a basis for judgment for subsequent response actions.

[0075] In step S3, the abnormal response mechanism of the solution is first clarified, defining the abnormal triggering conditions as signal loss or abnormality, and exceeding the standard time. Two core response methods are given: early warning and shutdown / locking. By associating the corresponding early warning with four types of signals, the pertinence of the early warning is clarified, that is, different early warning types correspond to different stages of signal abnormality, thereby improving operation and maintenance efficiency. By defining the core control actions of shutdown and locking cylinders, it is ensured that dangerous or unqualified production processes can be quickly terminated when abnormalities occur, ensuring equipment safety and product quality. Among them, the standard timing interval is the core timing judgment benchmark for abnormal detection of the entire stamping process of caster brackets. Specifically, it is defined as: the reasonable range of actual time required for the normal operation of the corresponding signals (feeding signal, pushing signal, discharging signal, reset signal) of each stage of the stamping process (feeding, pushing, discharging, reset) in a pre-set manner. By comparing the actual time of each signal with this interval, it is possible to accurately determine whether the timing of the signal operation in each stage is abnormal.

[0076] Specifically, step S3 includes the following sub-steps:

[0077] S301. Real-time acquisition of edge position signals and belt tension signals of the material belt, both of which are feeding signals: clarifying the core detection signal types in the feeding stage, and concretizing the "feeding signal" into "edge position signal" and "belt tension signal", clarifying the data acquisition direction and source of abnormal detection in the feeding stage, providing direct data support for the subsequent judgment of belt offset and belt tension value, and is a prerequisite for abnormal detection in the feeding stage.

[0078] S302. Determine whether the material strip offset corresponding to the edge position signal exceeds the preset offset threshold, and simultaneously determine whether the tension value corresponding to the material strip tension signal exceeds the preset tension range: Clarify the judgment criteria for anomalies during the feeding stage, converting the collected edge position and tension signals into quantifiable judgment indicators, namely material strip offset and tension value. Establish quantitative judgment boundaries through preset offset thresholds and preset tension ranges to improve the accuracy and operability of detection. Employing simultaneous judgment logic covers two core anomaly scenarios during the feeding stage: material strip offset and tension anomalies, avoiding missed anomalies caused by single signal detection, and providing a trigger basis for subsequent warnings or shutdown actions. The preset offset threshold is the core quantitative judgment benchmark for anomaly detection during the caster bracket stamping feeding stage. Specifically, it is defined as a pre-set critical value used to determine whether the material strip has offset. By comparing the actual offset corresponding to the material strip edge position signal with this threshold, it is possible to accurately determine whether the material strip offset during the feeding stage is abnormal. The preset offset threshold is a fixed value, set based on the actual caster bracket stamping feeding scenario. The preset tension range is a core quantitative benchmark used to determine whether the material belt tension is normal during the stamping and feeding process of the caster bracket. Specifically, it is defined as a pre-set range of tension values ​​required for normal material belt feeding. By comparing the actual tension value corresponding to the material belt tension signal with this range, it is possible to accurately determine whether there is any abnormality in the material belt tension during the feeding stage. The preset tension range is a fixed value, set based on the actual stamping and feeding scenario of the caster bracket.

[0079] S303. When the material belt offset intermittently exceeds the preset offset threshold, or the tension value intermittently exceeds the preset tension range, a feeding warning is triggered. The feeding warning includes generating voice and text prompts, displaying abnormal data of material belt offset and tension value on the local display unit, and controlling the feeding mechanism to reduce the feeding speed and shorten the acquisition interval between the edge position signal and the material belt tension signal. A response strategy is defined for non-serious abnormal situations during the feeding stage. By intermittently exceeding the preset offset threshold / preset tension range, the severity of the abnormality is distinguished, and a feeding warning is triggered accordingly, rather than directly stopping the machine. This achieves a graded response, balancing production continuity and abnormal control needs. The specific implementation form of the feeding warning is clarified, such as voice and text prompts and abnormal data visualization, ensuring that maintenance personnel can quickly perceive the abnormality type and specific parameters, improving response efficiency. Targeted parameter adjustment measures are designed, such as reducing the feeding speed and shortening the acquisition interval between the edge position signal and the material belt tension signal, to reduce the risk of abnormality escalation through proactive intervention, while improving the sensitivity of subsequent signal monitoring, forming a closed-loop control of "early warning, intervention, and enhanced monitoring."

[0080] S304. When the material strip offset exceeds the preset offset threshold for three consecutive stamping cycles, or the tension value exceeds the preset tension range for three consecutive stamping cycles and the fluctuation range continues to increase, immediately control the press to stop and lock the material strip and cylinder feeding actions: Define the response strategy when a serious / continuous abnormal situation occurs during the feeding stage. Define the boundary of serious abnormality by three consecutive stamping cycles and a continuous increase in fluctuation range, and trigger the immediate stop and lock actions accordingly to avoid the abnormality from expanding and causing batch product scrapping or equipment damage; clarify the specific objects of the stop and lock actions, specifically the press, material strip, and cylinder feeding actions, to ensure that all production actions related to feeding can be quickly terminated when an abnormality occurs, and improve the effectiveness of control; form a hierarchical response system with the feeding warning in step S303, clarify the hierarchical operation logic of intermittent abnormality warning and continuous abnormality stop, and make the abnormal response during the feeding stage more hierarchical and practically instructive.

[0081] S305. Collect and store the time-series data of belt offset, tension fluctuation data, and belt operating parameters during the abnormal feeding stage: Establish the data traceability foundation for abnormal feeding by collecting the time-series data of belt offset, tension fluctuation data, and belt operating parameters during the abnormal feeding stage to provide complete data support for subsequent fault location; Emphasize the timeliness and specificity of the data, only collect data during the abnormal stage to ensure the accuracy of fault analysis and avoid the waste of storage resources caused by indiscriminate data collection, lay the groundwork for subsequent fault diagnosis steps, and improve the closed-loop logic of "detection, response, and traceability" during the feeding stage.

[0082] S306. Based on the timing data of the belt offset, the tension fluctuation data, and the belt operating parameters, locate the cause of the belt offset or tension abnormality: realize the fault tracing function of feeding abnormality. By correlating and analyzing the stored multi-dimensional data, such as the timing data of the belt offset, the tension fluctuation data, and the belt operating parameters, accurately locate the root cause of the fault, such as the mechanical cause of the belt deviation, the driving cause of the tension abnormality, etc., solve the pain point of existing technologies that can only detect abnormalities but cannot locate faults, and reduce the fault troubleshooting time.

[0083] S307. Generate a material feeding fault diagnosis report including fault type and abnormal feeding signal, and display it visually through the local display unit: output the fault diagnosis results of feeding abnormality, clarify the core content of the diagnosis report, including fault type and abnormal signal, and ensure that maintenance personnel can quickly obtain key fault information; adopt a visual display format to improve the readability and transmission efficiency of fault information; complete the closed-loop logic of "detection, response, traceability and diagnosis" in the feeding stage.

[0084] S308. Real-time acquisition of the first stroke information and second stroke information generated by the actions of the two cylinders during the pushing process. The first stroke information and the second stroke information are both pushing signals: the core detection signals of the material pushing stage. The pushing signals are defined as the first stroke information and the second stroke information of the two cylinders during the pushing process. This establishes the data acquisition foundation for abnormal detection in the pushing stage and provides direct raw data support for subsequent synchronization rate calculation. It is a prerequisite for abnormal judgment in the pushing stage.

[0085] S309. Real-time calculation and analysis of the synchronization rate between the first and second stroke information to determine if it conforms to the preset synchronization rate: Establish a core judgment indicator for anomalies in the pushing stage. Quantify the coordination and consistency of the pushing actions of the two cylinders through the synchronization rate, transforming discrete stroke information into quantifiable judgment criteria, thus improving the accuracy and scientific rigor of anomaly detection. Introduce the preset synchronization rate as a judgment benchmark to clarify the acceptable boundary of the pushing action coordination, providing clear triggering conditions for subsequent graded responses. Following the signal acquisition in step S308, form a logical chain of signal acquisition, indicator calculation, and conformity analysis to achieve targeted detection of anomalies in the pushing stage, filling the gap in pushing coordination control outside the feeding stage. The preset synchronization rate is the core quantitative judgment benchmark for anomaly detection in the caster bracket stamping pushing stage. Specifically, it is defined as a pre-set critical value used to judge the coordination and consistency of the pushing actions of the two cylinders. By comparing the actual synchronization rate calculated from the pushing stroke information of the two cylinders with this value, it is possible to accurately determine whether the cylinder coordination action in the pushing stage is abnormal. The preset synchronization rate is a fixed value, set based on the actual application of the cylinders in the caster bracket stamping pushing scenario.

[0086] S310. When the synchronization rate is less than the preset synchronization rate, immediately control the punch press to stop and lock the cylinder action: Define the response strategy when a serious abnormal situation occurs during the material pushing stage. By defining the serious abnormal scenario of the failure of the two cylinders to coordinate the material pushing actions through the synchronization rate being less than the preset synchronization rate, the corresponding immediate stop and cylinder action locking are triggered to avoid risks such as product forming accuracy defects and equipment jamming caused by asynchronous material pushing. It is clear that the core objects of the stop and lock are the punch press and cylinder action, ensuring that the material pushing related production process is quickly terminated when an abnormality occurs, and ensuring equipment safety and product quality.

[0087] S311. When the synchronization rate is greater than or equal to the preset synchronization rate, analyze the trend of the synchronization rate: Define a predictive control strategy for the qualified state during the material pushing stage. For scenarios where the synchronization rate meets the preset requirements, control is not terminated, but the trend of change is further analyzed to achieve forward-looking monitoring of the material pushing coordination and avoid potential abnormal risks in advance; build the basis for hierarchical control during the material pushing stage by distinguishing between two scenarios: "stopping when the synchronization rate is not up to standard" and "trend analysis when the synchronization rate is up to standard", laying the logical foundation for the detailed response to the change trend of the synchronization rate in the future; extend the depth of abnormal control during the material pushing stage, upgrading from "only detecting the current abnormality" to "taking into account both the current qualified state and the prediction of future trends", improving the comprehensiveness and forward-looking nature of the technical solution.

[0088] Specifically, step S311 also includes the following sub-steps:

[0089] S3111. When the synchronization rate intermittently decreases, a push-material warning is triggered. This warning includes generating voice and text prompts and displaying them in a pop-up window on the local display unit; recording the time of each intermittent decrease and the corresponding synchronization rate value; simultaneously controlling two cylinders to reduce the push-material speed to improve push-material stability; shortening the interval between stroke information collection during subsequent push-material processes; and improving the sensitivity to monitoring changes in the synchronization rate. A warning and control strategy is defined for the "synchronization rate meets the standard but intermittently decreases" phase during the push-material stage. By defining potential abnormal scenarios through "intermittent decreases," a push-material warning is triggered instead of a direct shutdown, achieving refined proactive warning and intervention. Control measures are implemented to balance production continuity with risk prediction requirements. A multi-dimensional approach to material feeding warnings is defined: on the one hand, voice, text prompts, and pop-up displays ensure maintenance personnel can quickly perceive potential anomalies; on the other hand, time-series data is recorded to provide a basis for subsequent fault tracing. Targeted proactive intervention measures are designed, such as reducing cylinder feeding speed to improve stability and shortening the interval for collecting stroke information during subsequent feeding processes to improve monitoring sensitivity. This upgrades from "passive response" to "proactive risk avoidance," effectively preventing intermittent reduction trends from worsening into continuous reductions and improving the stability of the feeding process. Stroke information refers to the first stroke information and the second stroke information.

[0090] S3112. When the synchronization rate decreases continuously, immediately stop the punch press and lock the cylinder action: Clarify the serious risk response strategy for "synchronization rate meets the standard but continuously decreases" in the material pushing stage. Define the escalation scenario of potential coordination failure risk through "continuous decrease", and trigger the immediate stop and cylinder locking action accordingly to avoid subsequent material pushing coordination failure due to continuous decrease in synchronization rate, which may lead to product defects or equipment failure. Together with the material pushing warning in step S3111, form a graded response system for the qualified state of the material pushing stage. Intermittent decrease triggers the material pushing warning, and continuous decrease triggers the immediate stop. Clarify the control boundaries of different trend scenarios, making the predictive control logic of the material pushing stage more rigorous and operable.

[0091] Specifically, step S3112 further includes the following sub-steps:

[0092] S31121. Real-time acquisition and storage of real-time stroke data, pusher driving force data, and synchronization rate change data of the two cylinders during the continuous reduction phase of the synchronization rate. Record the time point when the synchronization rate first falls below the preset synchronization rate, the duration of continuous reduction, and the final synchronization rate value: establish a data traceability foundation for severe abnormal trends in pusher operation. For the continuous reduction phase of the synchronization rate, accurately collect multi-dimensional core data (stroke, driving force, and synchronization rate time-series data) and key time node information to provide a comprehensive and accurate data source for subsequent fault location. Emphasize the "targeted" (focusing only on the abnormal phase) and "time-series" nature of data acquisition to ensure the accuracy of fault analysis and avoid resource waste caused by indiscriminate data acquisition. Clarify the key indicators of data recording (first reduction time point, duration, and final value) to provide a basis for subsequent analysis of the rate, degree, and scope of impact of the synchronization rate reduction, and improve the accuracy of fault tracing.

[0093] S31122. Based on stored stroke data, pusher driving force data, and synchronization rate change data, analyze the target cylinder with stroke lag or abnormal pusher driving force fluctuations in two cylinders to locate the source of the continuously decreasing synchronization rate: achieve accurate fault location for severe abnormal pusher trends, and clarify the core causes of the fault (such as stroke lag / driving force fluctuations) and the specific fault carrier (target cylinder) through correlation analysis of multi-dimensional stored data, solving the pain point of existing technologies that can only detect anomalies but cannot locate the source of the fault; focus on the differential analysis of the two cylinders, eliminate interference from normal cylinders, directly lock the faulty cylinder, shorten the fault investigation time, and improve operation and maintenance efficiency.

[0094] S31123. Generate a feeding fault diagnosis report that includes fault type (such as continuous decrease in synchronization rate), fault source (target cylinder number), fault timing data, and abnormal feeding signals. The report is then visualized on a local display unit. The report outputs a "standardized fault diagnosis result" indicating a severe abnormal feeding trend, clearly defining the core content of the diagnosis report. This ensures that maintenance personnel can quickly and intuitively obtain key fault information, such as fault type, location, timing data, and abnormal signals, thus lowering the maintenance threshold. The visualization presentation on a local display unit improves the efficiency of fault information transmission and facilitates maintenance personnel in quickly developing repair plans.

[0095] S312. Real-time acquisition of the shading duration and shading intensity of the product passing through the discharge port. The shading duration and shading intensity are both discharge signals: the core detection signals of the material discharge stage. The abstract "discharge signal" is defined as "shading duration" and "shading intensity", which establishes the data acquisition basis for abnormal detection in the discharge stage. The shading characteristics of the product when passing through the discharge port are used as the detection basis. This adapts to the actual scenario of product discharge after caster bracket stamping, and provides direct and quantifiable data support for subsequent abnormal judgment. It is a prerequisite for abnormal detection in the discharge stage.

[0096] S313. Determine whether the shading duration is within the preset discharge time range, and simultaneously determine whether the shading intensity reaches the preset shading threshold: Establish core judgment criteria for anomalies in the discharge stage, transforming the collected raw shading signals into quantifiable judgment indicators, specifically shading duration and shading intensity. Establish clear acceptable boundaries through preset discharge time ranges and preset shading thresholds to improve the accuracy and operability of anomaly detection. Employ simultaneous judgment logic to cover two core anomaly scenarios in the discharge stage: abnormal product discharge speed / jamming leading to abnormal shading duration, and product failure / incomplete discharge leading to insufficient shading intensity, avoiding missed anomalies due to single signal detection. The preset discharge time range is the core quantitative benchmark for anomaly detection in the caster bracket stamping discharge stage. Specifically, it is defined as: a pre-set reasonable duration range for the shading signal when the product normally passes through the discharge port. By comparing the actual shading duration of the product passing through the discharge port with this range, it is possible to accurately determine whether the product discharge process in the discharge stage is abnormal. The preset light-blocking threshold is the core quantitative benchmark for abnormal detection during the stamping and unloading stage of the caster bracket. Specifically, it is defined as the minimum critical intensity value that the light-blocking signal must reach when the product passes through the unloading port normally. By comparing the actual light-blocking intensity of the product passing through the unloading port with this threshold, it is possible to accurately determine whether the product passes through the unloading port normally during the unloading stage.

[0097] S314. When the duration of light shading at any discharge port exceeds the preset discharge duration range, or the intermittent light shading intensity fails to reach the preset light shading threshold, a discharge warning is triggered. The discharge warning includes generating voice and text prompts, displaying the corresponding discharge port number in a pop-up window on the local display unit, recording the timing data of each anomaly, and simultaneously controlling and adjusting the discharge speed of the corresponding side cylinder to improve the stability of the discharge push. A response strategy for "minor / intermittent anomalies" in the discharge stage is defined, and the severity of the anomaly is determined by "intermittently exceeding the preset discharge duration range / failing to reach the preset light shading threshold". Instead of directly shutting down the machine, the system triggers a discharge warning, achieving a tiered response and balancing production continuity with anomaly control requirements. The system clarifies the multi-dimensional implementation of discharge warnings: on the one hand, it uses voice, text prompts, and pop-up window notifications of the discharge port number to ensure maintenance personnel can quickly locate abnormal discharge ports, improving response efficiency; on the other hand, it records time-series data to provide a basis for subsequent fault tracing. Targeted proactive intervention measures are designed, such as adjusting the discharge speed of the corresponding side cylinder to accurately match abnormal discharge port scenarios, and optimizing discharge power to improve pushing stability, effectively preventing the expansion of intermittent anomalies.

[0098] S315. When no valid discharge signal is collected from any discharge port for two consecutive stamping cycles, or the shading time exceeds the preset discharge time range for two consecutive cycles without any recovery trend, the press is immediately stopped and the cylinder discharge action is locked. The valid discharge signal is a detection signal where the shading time is within the preset discharge time range and the shading intensity reaches the preset shading threshold. The response strategy for "serious / continuous abnormality" in the discharge stage is defined. The boundary of serious abnormality is defined by the failure to collect a valid discharge signal for two consecutive stamping cycles and the shading time exceeding the preset discharge time range for two consecutive cycles without any recovery trend. This triggers an immediate stop and locks the cylinder discharge action to avoid product accumulation, equipment jamming, or subsequent stamping process disorder caused by abnormal discharge. The definition of a valid discharge signal is clarified to provide an accurate benchmark for abnormality judgment and strengthen the rigor of the judgment standard. The core objects of the stop and lock are clearly defined, specifically the press and cylinder discharge actions, to ensure that the discharge-related production process is quickly terminated when an abnormality occurs, ensuring equipment safety and subsequent production order.

[0099] S316. Collect and store data on shading duration, cylinder discharge driving force, and discharge port operating condition images during the abnormal discharge stage: Establish a multi-dimensional data traceability foundation for abnormal discharge. For the abnormal discharge stage, in addition to collecting the core shading duration data, add cylinder discharge driving force data and discharge port operating condition images to provide a more comprehensive and accurate data source for subsequent fault location. Emphasize the targeted nature of data collection, focusing only on the abnormal stage, which ensures the accuracy of fault analysis and avoids the waste of resources caused by indiscriminate data collection. At the same time, add image data to adapt to the traceability requirements of visually identifiable faults such as product jamming at the discharge port, and improve the adaptability of fault traceability.

[0100] S317. Based on shading duration data, cylinder discharge driving force data, and discharge port operating condition image data, the fault source of product jamming or insufficient cylinder discharge power is located: This achieves precise fault location when discharge is abnormal. By correlating and analyzing multi-dimensional data, such as shading duration data reflecting product passage status, cylinder discharge driving force data reflecting cylinder power status, and discharge port operating condition image data visually presenting the operating condition, two core fault sources are accurately identified: product jamming and insufficient cylinder discharge power. This addresses the pain point of existing technologies that can only detect discharge abnormalities but cannot pinpoint the root cause of the fault. Combined with the visual advantages of image data, the specific location of product jamming can be directly located, which is more intuitive and accurate than single signal analysis.

[0101] S318. Generate a discharge fault diagnosis report including fault type, abnormal discharge signal, and corresponding cylinder number, and simultaneously display a fault location diagram on the local display unit: clearly define the core content of the diagnosis report, specifically the fault type, abnormal signal, and corresponding cylinder number, ensuring that maintenance personnel can quickly obtain key fault information and lower the maintenance threshold; add a visual display of the fault location diagram, combined with the jamming location and other information located in step S317, to intuitively present the fault location, further improve the efficiency of fault information transmission, and facilitate maintenance personnel to quickly formulate maintenance plans.

[0102] S319. Real-time acquisition of the first and second stroke information generated by the actions of the two cylinders during the reset process. The first and second stroke information are both reset signals: the core detection signals of the concrete reset stage. The abstract reset signal is defined as the first and second stroke information of the two cylinders during the reset process, which establishes the data acquisition foundation for abnormal detection in the reset stage. For the key final stage of cylinder reset, the acquisition of stroke-related information provides direct raw data support for subsequent deviation judgment. It is the premise of abnormal detection in the reset stage and ensures that the standardization of the reset action can be accurately monitored.

[0103] S320. Real-time calculation and analysis of the return deviation between the first and second return information to determine if it exceeds the preset return deviation: Establishing a core judgment indicator for anomalies in the reset phase, quantifying the coordination and consistency of the two cylinder reset actions through return deviation, transforming discrete return information into quantifiable judgment criteria, and accurately capturing the core anomaly risk of "asynchronous cylinder actions" in the reset phase; introducing a "preset return deviation" as a judgment benchmark, clarifying the qualified boundary of reset action coordination, providing clear triggering conditions for subsequent graded responses, and improving the accuracy and operability of anomaly detection; following the signal acquisition in step S319, forming a logical chain of "signal acquisition, deviation calculation, and compliance analysis," realizing targeted detection of anomalies in the reset phase, filling the gap in the lack of coordination control in the reset process in existing technologies. Among them, the preset return deviation is the core quantitative judgment benchmark for anomaly detection in the caster bracket stamping reset phase, specifically defined as: a pre-set critical value used to judge the coordination and consistency of the two cylinder reset (return) actions. By comparing the actual return deviation calculated from the return information of the two cylinders with this value, it is possible to accurately determine whether the cylinder coordination action in the reset phase is abnormal.

[0104] S321. When the return deviation is greater than or equal to the preset return deviation, in order to avoid scrapping the product in the current stamping cycle and reduce production losses, the press is controlled to decelerate and stop after the current stamping cycle is completed. At the same time, the cylinder reset action is locked. Define a differentiated response strategy for "serious abnormality" in the reset stage. Define the serious abnormality scenario of reset coordination failure by "return deviation ≥ preset return deviation". At the same time, introduce the flexible control logic of "stopping after completing the current stamping cycle". This is different from the "immediate stop" in the feeding, pushing and unloading stages mentioned above. It can avoid scrapping the product in the current cycle due to mid-cycle stop and prevent the abnormality from expanding and affecting the production of subsequent cycles, thus balancing loss control and production continuity requirements. Clarify the core logic of the response action: first decelerate, complete the current cycle, then stop and lock the cylinder reset action to ensure a smooth shutdown process. At the same time, accurately lock the reset-related actions to prevent abnormal reset from interfering with subsequent processes. Through differentiated response, product scrapping is avoided, losses are reduced, and the rationality and pertinence of the technical solution are strengthened.

[0105] S322. When the retrace deviation is less than the preset retrace deviation, analyze the trend of the retrace deviation: clarify the predictive control strategy for the reset phase under qualified conditions. For scenarios where the retrace deviation meets the preset requirements, control is not terminated, but the trend is further analyzed to achieve forward-looking monitoring of reset coordination and avoid potential abnormal risks in advance, such as the retrace deviation gradually increasing and eventually exceeding the preset retrace deviation; construct the basis for hierarchical control in the reset phase by distinguishing between two scenarios: trend analysis when the deviation meets the standard and flexible shutdown when the deviation does not meet the standard, laying the logical foundation for the subsequent detailed response (early warning / shutdown) to the trend of retrace deviation changes; extend the depth of abnormal control in the reset phase, upgrading from "only detecting the current abnormality" to "taking into account both the current qualified state and the prediction of future trends", improving the comprehensiveness of detection and prevention.

[0106] Specifically, step S322 further includes the following sub-steps:

[0107] S3221. When the return deviation shows an intermittent increasing trend, a reset warning is triggered. The reset warning includes generating text prompts and displaying them in a pop-up window on the local display unit, recording the time node of each intermittent increase and the corresponding deviation value, and controlling the punch press to maintain the current operating speed and shorten the interval of subsequent stamping cycles to increase the monitoring frequency of return deviation. The warning and control strategy for "return deviation meets the standard but intermittently increases" in the reset phase is clarified. The potential abnormal scenario is defined by "intermittent increase" to trigger the reset warning instead of directly stopping the machine, realizing a forward-looking warning and refined control with enhanced monitoring. This ensures the continuity of current production and avoids the risk of deviation expansion in advance. The multi-dimensional implementation of the reset warning is clarified: on the one hand, text prompts and pop-up windows ensure that maintenance personnel can quickly perceive potential abnormalities; on the other hand, recording the time node and the corresponding deviation value provides a basis for subsequent fault tracing. Targeted control measures are designed, such as maintaining the current operating speed, shortening the stamping cycle interval, and increasing the monitoring frequency, to adapt to the scenario of "return deviation not exceeding the standard but showing an increasing trend" in the reset phase. This does not affect the current production rhythm, but can accurately track changes in return deviation and detect abnormalities in a timely manner by increasing the monitoring frequency.

[0108] S3222. When the return deviation shows a continuous increasing trend, immediately control the press to stop and lock the cylinder reset action: Clarify the serious risk response strategy for "deviation meets the standard but continues to increase" in the reset stage. By defining the potential reset coordination failure risk through "continuous increase", the system will trigger an immediate stop and lock the cylinder reset action accordingly. This will prevent the return deviation from exceeding the preset return deviation due to continuous increase, which could lead to subsequent reset action failure, equipment jamming, or affect the accuracy of the next round of stamping process. Together with the reset warning in step S3221, this forms a graded response system for the qualified state of the reset stage. Specifically, intermittent increase will trigger a reset warning, and continuous increase will trigger an immediate stop. This clarifies the control boundaries for different trend scenarios, making the predictive control logic of the reset stage more rigorous and operable.

[0109] Specifically, step S3222 further includes the following sub-steps:

[0110] S32221. Real-time acquisition and storage of return speed data, return driving force fluctuation data, and return deviation change data of two cylinders during the continuous increase phase of return deviation: Establishing a "data traceability foundation" for severe abnormal reset trends. For the continuous increase phase of return deviation, accurately collect multi-dimensional core data, specifically return speed data, return driving force fluctuation data, and return deviation change data, providing a comprehensive and accurate data source for subsequent fault location; Emphasizing the targeted and time-series nature of data acquisition, focusing only on the abnormal phase, ensuring that fault analysis can accurately match the process of increasing deviation, and avoiding resource waste caused by indiscriminate data acquisition. The collected data dimensions are aligned with the core parameters of cylinder action during the reset phase, such as return speed and return driving force, adapting to the fault analysis scenario of reset anomalies.

[0111] S32222: Based on return speed data, return driving force fluctuation data, and return deviation change data, analyze the target cylinder with abnormal stroke growth or unstable return driving force among two cylinders to locate the fault source of continuously increasing return deviation: achieve "precise fault location" for severe abnormal reset trend. Through correlation analysis of multi-dimensional stored data, clarify the core cause of the fault (such as abnormal stroke growth or unstable return driving force) and the specific fault carrier (target cylinder), solving the pain point of existing technologies that can only detect reset abnormalities but cannot locate the fault source; focus on the differential analysis of two cylinders, eliminate interference from normal cylinders, directly lock the faulty cylinder, shorten the fault investigation time, and improve operation and maintenance efficiency.

[0112] S32223 generates a reset fault diagnosis report including fault type (e.g., continuously increasing return deviation), fault source (target cylinder number), fault timing data, and fault reset signal, which is visualized through a local display unit. It outputs a "standardized fault diagnosis result" indicating a severe abnormal reset trend, clearly defining the core content of the diagnosis report and ensuring that maintenance personnel can quickly and intuitively obtain key fault information, such as fault type, location, timing data, and abnormal signals, thus lowering the maintenance threshold. The visualization presentation using a local display unit improves the efficiency of fault information transmission, facilitating rapid maintenance personnel development of repair plans. It completes the closed-loop logic of "abnormal trend, shutdown, data acquisition, fault location, and diagnostic output" in the reset phase, signifying that a complete "abnormal detection, response, tracing, and diagnosis" control chain has been formed for each stage of the entire stamping process (feeding, pushing, unloading, and reset), enabling the technical solution to possess full-process, full-scenario abnormal control capabilities.

[0113] Please refer to Figure 2 This application provides a caster bracket feeding and discharging stamping induction control system, which corresponds to the method in the above embodiments. Specifically, the system includes:

[0114] The first acquisition module 201 is used to acquire in real time the feeding signal, pushing signal, discharging signal, reset signal and the actual time corresponding to each of the above signals. The feeding signal is generated by the feeding action of the material belt and the two cylinders. The discharging signal is generated by the discharging action of the two cylinders and the detection action of the product passing through the discharge port. The reset signal is generated by the return reset action of the two cylinders.

[0115] The first control module 202 is used to detect and determine in real time whether the feeding signal, discharging signal, reset signal and actual time used in the same stamping cycle are abnormal, according to the order of feeding, pushing, discharging and resetting.

[0116] The second control module 203 is used to trigger a corresponding warning or control the punch press to stop and lock the cylinder action when any of the above signals are missing, abnormal or the actual time exceeds the standard timing interval. The corresponding warnings include feeding warning, pushing warning, discharging warning and reset warning.

[0117] As can be seen from the above, the caster bracket feeding and discharging stamping induction control method and system provided in this application has the following advantages:

[0118] 1. Achieve orderly control of the entire stamping process: covering the four core processes of feeding, pushing, discharging, and resetting, and forming a complete control chain of "signal acquisition, anomaly judgment, response and handling, and fault tracing" through the logic of full-process signal acquisition, process-sequence detection and anomaly graded response, so as to avoid the spread of anomalies in a single process from affecting the overall production rhythm.

[0119] 2. Establish a graded response mechanism to balance production continuity and risk control: trigger early warnings and link parameter adjustments (such as speed reduction and shortening of data acquisition intervals) for intermittent anomalies in each process (such as material belt deviation exceeding the standard intermittently or synchronization rate decreasing intermittently); trigger shutdown and locking actions for continuous anomalies (such as exceeding the standard for multiple consecutive cycles or deviation increasing continuously). This reduces unnecessary shutdowns and can stop losses in time, avoiding the scrapping of batch products or equipment damage.

[0120] 3. Improve the accuracy of anomaly detection and reduce subjective judgment errors: Introduce quantitative judgment benchmarks such as preset offset threshold, preset tension range, and preset synchronization rate to transform abstract motion anomalies into comparable numerical indicators, ensuring that the anomaly detection standards of each process are consistent and the judgment is accurate, thus guaranteeing the stamping and forming accuracy of caster brackets.

[0121] 4. Optimize fault tracing efficiency and shorten maintenance downtime: After abnormal shutdown of each process, core operating data is collected synchronously to accurately locate the source of the fault (such as the target cylinder or the product jamming position) and generate a visual diagnostic report, reducing the difficulty of fault diagnosis, shortening maintenance time and improving equipment uptime.

[0122] 5. Reduce production losses and improve economic efficiency: The reset process adopts a flexible control strategy of "stopping the machine after completing the current stamping cycle" to avoid scrapping products in the current cycle; the full-process early warning mechanism intervenes in potential anomalies in advance to further reduce production losses caused by failures.

[0123] In the embodiments provided in this application, it should be understood that the disclosed systems and methods can be implemented in other ways. The system embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and there may be other division methods in actual implementation. Furthermore, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the coupling or direct coupling or communication connection shown or discussed may be through some communication interface; the indirect coupling or communication connection between systems or units may be electrical, mechanical, or other forms.

[0124] Furthermore, the units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0125] Furthermore, the functional modules in the various embodiments of this application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0126] In this document, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, without necessarily requiring or implying any such actual relationship or order between these entities or operations.

[0127] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for controlling the feeding and discharging of a caster bracket using a stamping induction sensor, characterized in that, The method includes the following steps: The feeding signal, pushing signal, discharging signal, and reset signal, as well as the actual time taken for each of the above signals, are acquired in real time. The feeding signal is generated by the feeding action of the material belt, the pushing signal is generated by the pushing action of the two cylinders, the discharging signal is generated by the discharging action of the two cylinders and the detection action of the product passing through the discharge port, and the reset signal is generated by the return reset action of the two cylinders. According to the process sequence of feeding, pushing, discharging, and resetting, the system detects and judges in real time whether any abnormalities occur in the feeding signal, pushing signal, discharging signal, resetting signal, and actual time usage within the same stamping cycle. When any of the above signals is missing, abnormal, or the actual time exceeds the standard timing interval, the corresponding warning is triggered or the punch press is stopped and the cylinder action is locked. The corresponding warnings include feeding warning, pushing warning, discharging warning, and reset warning. When any of the above signals is missing, abnormal, or the actual time taken exceeds the standard timing interval, the steps to trigger the corresponding warning or control the punch press to stop and lock the cylinder action also include: The first return information and the second return information generated by the two cylinders during the reset process are collected in real time. Both the first return information and the second return information are reset signals. Real-time calculation of the return deviation between the first and second return information and analysis of whether it exceeds the preset return deviation; When the return deviation is greater than or equal to the preset return deviation, in order to avoid scrapping the products in the current stamping cycle and reduce production losses, the press is controlled to decelerate and stop after the current stamping cycle is completed, while the cylinder reset action is locked. When the retrace deviation is less than the preset retrace deviation, analyze the trend of the retrace deviation. When the retrace deviation is less than the preset deviation, the steps for analyzing the trend of the retrace deviation also include: When the return deviation shows an intermittent increasing trend, a reset warning is triggered. The reset warning includes generating text prompt information and displaying it in a pop-up window on the local display unit, recording the time node of each intermittent increase and the corresponding deviation value, and controlling the punch press to maintain the current running speed and shorten the interval of subsequent stamping cycles to increase the monitoring frequency of return deviation. When the return deviation shows a continuous increasing trend, immediately stop the punch press and lock the cylinder reset action; When the return deviation shows a continuous increasing trend, the steps to control the punch press to stop immediately and lock the cylinder reset action also include: Real-time acquisition and storage of return speed data, return driving force fluctuation data, and return deviation change data of two cylinders during the continuous increase of return deviation; Based on return speed data, return driving force fluctuation data, and return deviation change data, the target cylinder with abnormal stroke growth or unstable return driving force in the two cylinders is analyzed to locate the fault source of continuous increase in return deviation. Generate a reset fault diagnosis report that includes fault type, fault source, fault timing data and fault reset signal, and display it visually through the local display unit.

2. The caster bracket feeding and discharging stamping induction control method according to claim 1, characterized in that, When any of the above signals is missing, abnormal, or the actual time taken exceeds the standard timing interval, the steps to trigger the corresponding warning or control the punch press to stop and lock the cylinder action also include: Real-time acquisition of edge position signals and belt tension signals of the material belt, both of which are feeding signals; Determine whether the material strip offset corresponding to the edge position signal exceeds the preset offset threshold, and at the same time determine whether the tension value corresponding to the material strip tension signal exceeds the preset tension range; When the material belt offset intermittently exceeds the preset offset threshold, or the tension value intermittently exceeds the preset tension range, a feeding warning is triggered. The feeding warning includes generating voice and text prompts, displaying abnormal data of material belt offset and tension value on the local display unit, and controlling the feeding mechanism to reduce the feeding speed and shorten the acquisition interval between the edge position signal and the material belt tension signal. When the material strip offset exceeds the preset offset threshold for three consecutive stamping cycles, or the tension value exceeds the preset tension range for three consecutive stamping cycles and the fluctuation range continues to increase, the press will be stopped immediately and the material strip and cylinder feeding action will be locked. Collect and store the timing data of belt offset, tension fluctuation data and belt operation parameters during the abnormal feeding stage; Based on the timing data of belt offset, tension fluctuation data and belt operating parameters, the cause of belt offset or tension abnormality is located. Generate a material feeding fault diagnosis report that includes fault type and abnormal feeding signal, and display it visually through the local display unit.

3. The caster bracket feeding and discharging stamping induction control method according to claim 2, characterized in that, When any of the above signals is missing, abnormal, or the actual time taken exceeds the standard timing interval, the steps to trigger the corresponding warning or control the punch press to stop and lock the cylinder action also include: Real-time acquisition of the first stroke information and the second stroke information generated by the two cylinders during the pushing process, both of which are pushing signals; Real-time calculation of the synchronization rate between the first and second travel information and analysis of whether it meets the preset synchronization rate; When the synchronization rate is less than the preset synchronization rate, immediately control the punch press to stop and lock the cylinder action; When the synchronization rate is greater than or equal to the preset synchronization rate, analyze the trend of the synchronization rate.

4. The caster bracket feeding and discharging stamping induction control method according to claim 3, characterized in that, When the synchronization rate is greater than or equal to the preset synchronization rate, the steps for analyzing the trend of the synchronization rate also include: When the synchronization rate decreases intermittently, a push warning is triggered. The push warning includes generating voice and text prompts and displaying them in a pop-up window on the local display unit, recording the time node of each intermittent decrease and the corresponding synchronization rate value, and controlling two cylinders to reduce the push speed to improve push stability, shorten the interval of stroke information collection in the subsequent push process, and improve the sensitivity of monitoring changes in synchronization rate. When the synchronization rate decreases continuously, immediately stop the punch press and lock the cylinder action.

5. The caster bracket feeding and discharging stamping induction control method according to claim 4, characterized in that, When the synchronization rate continuously decreases, the steps to immediately stop the punch press and lock the cylinder action also include: Real-time acquisition and storage of real-time stroke data, material pushing driving force data and synchronization rate change data of the two cylinders during the continuous reduction phase of synchronization rate, recording the time point when the synchronization rate first falls below the preset synchronization rate, the duration of continuous reduction and the final synchronization rate value. Based on the stored stroke data, pusher driving force data, and synchronization rate change data, the target cylinder with stroke lag or abnormal pusher driving force fluctuations in the two cylinders is analyzed to locate the source of the fault where the synchronization rate continuously decreases. Generate a feeding fault diagnosis report that includes fault type, fault source, fault timing data and abnormal feeding signal, and display it visually through the local display unit.

6. The caster bracket feeding and discharging stamping induction control method according to claim 5, characterized in that, When any of the above signals is missing, abnormal, or the actual time taken exceeds the standard timing interval, the steps to trigger the corresponding warning or control the punch press to stop and lock the cylinder action also include: The light-blocking duration and light-blocking intensity of the product passing through the discharge port are collected in real time. Both the light-blocking duration and the light-blocking intensity are discharge signals. Determine whether the shading time is within the preset discharge time range, and at the same time determine whether the shading intensity reaches the preset shading threshold. When the duration of light blocking at any discharge port exceeds the preset discharge duration range, or the duration of light blocking intensity does not reach the preset light blocking threshold, a discharge warning is triggered. The discharge warning includes generating voice and text prompts, displaying the corresponding discharge port number in a pop-up window on the local display unit, recording the timing data of each abnormality, and controlling and adjusting the discharge speed of the corresponding side cylinder to improve the stability of the discharge push. If no valid discharge signal is collected from any discharge port for two consecutive stamping cycles, or if the shading time exceeds the preset discharge time range for two consecutive cycles and there is no recovery trend, the press is immediately stopped and the cylinder discharge action is locked. The valid discharge signal is a detection signal in which the shading time is within the preset discharge time range and the shading intensity reaches the preset shading threshold. Collect and store data on the duration of shading, the driving force of cylinder discharge, and the working condition image data of the discharge port during the abnormal discharge stage; Based on the data of shading duration, cylinder discharge driving force, and discharge port working condition image data, the source of the product jamming or insufficient cylinder discharge power can be located. Generate a discharge fault diagnosis report that includes the fault type, abnormal discharge signal and corresponding cylinder number, and simultaneously display the fault location diagram on the local display unit.

7. A caster bracket feeding and discharging stamping induction control system, implementing the caster bracket feeding and discharging stamping induction control method according to claim 1, characterized in that, The system includes: The first acquisition module (201) is used to acquire in real time the feeding signal, pushing signal, discharging signal, reset signal and the actual time corresponding to each of the above signals. The feeding signal is generated by the feeding action of the material belt and the two cylinders. The discharging signal is generated by the discharging action of the two cylinders and the detection action of the product passing through the discharge port. The reset signal is generated by the return reset action of the two cylinders. The first control module (202) is used to detect and determine whether any abnormalities occur in the feeding signal, discharging signal, reset signal and actual time used within the same stamping cycle in real time according to the order of feeding, pushing, discharging and resetting. The second control module (203) is used to trigger a corresponding warning or control the punch press to stop and lock the cylinder action when any of the above signals are missing, abnormal or the actual time exceeds the standard timing interval. The corresponding warnings include feeding warning, pushing warning, discharging warning and reset warning.

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