Molding glass fiber reinforced plastic grating automatic yarn winding control system based on continuous interpolation algorithm

Abstract

The invention relates to the technical field of composite material processing control, in particular to a molded glass fiber reinforced plastic grating automatic yarn winding control system based on a continuous interpolation algorithm. In the automatic yarn winding process of the yarn winding pipe, a connection triggering threshold value is set when each action is close to the end, the position and state of the yarn winding pipe are detected in real time through a controller, and when the position and state of the yarn winding pipe reach the corresponding connection triggering threshold values, the controller conducts continuous interpolation on the basis of a pre-planned continuous interpolation algorithm. According to the method, the motion trail data of the next action is generated and sent to the servo shaft for driving the next action, and the next servo shaft is started in advance to accelerate in advance, so that the next action can be seamlessly connected at the moment when the previous action is completed; a continuous and smooth kinematic chain is formed among a plurality of actions through multi-axis cooperation, a large amount of ineffective time generated in the cyclic process of deceleration, stable stopping and re-acceleration of the servo shafts can be saved, and the production efficiency of the grating is obviously improved.

Description

Technical Field

[0001] This invention relates to the field of composite material processing control technology, and in particular to an automatic yarn winding control system for molded fiberglass grating based on a continuous interpolation algorithm. Background Technology

[0002] Molded fiberglass grating, as a high-performance composite material product, boasts numerous excellent properties such as lightweight, high strength, corrosion resistance, good insulation, and anti-slip properties, making it widely used in many fields including petrochemicals, marine engineering, construction, power, and wastewater treatment. In the petrochemical industry, its resistance to various chemical substances makes it commonly used as operating platforms and trench covers. In marine engineering, its excellent corrosion resistance makes it an ideal material for ship decks and offshore drilling platform walkways in harsh environments with high salinity and humidity. In construction, it can be used to make stair treads and railings, combining aesthetics and practicality. In the power industry, its excellent insulation properties ensure the safety of operators and equipment, making it commonly used in substations. In wastewater treatment plants, it effectively resists acid and alkali corrosion in wastewater and is used as gratings and platforms.

[0003] With the rapid development of various industries, the market demand for molded fiberglass gratings is showing a continuous growth trend. To meet this increasing market demand, improving production efficiency and product quality has become a key issue for molded fiberglass grating manufacturers. Our company's automatically wound yarn equipment (patent number: CN202321819920.7, patent name: An Automatic Yarn Winding System for Molded Fiberglass Grating) is a core piece of equipment in the molded fiberglass grating production process, and its performance directly affects production efficiency and product quality. Highly efficient and stable automatic yarn winding equipment can achieve precise yarn winding, improve the structural strength and stability of the grating, while reducing manual operation and lowering production costs.

[0004] Currently, our company's automatically wound yarn equipment for molded fiberglass grating utilizes a control system with an Inovance AM600 series PLC and eight servo axes, communicating via a bus. The Inovance AM600 series PLC boasts rich functionality and high reliability, finding wide application in industrial automation. In the production process of molded fiberglass grating, the yarn winding action is a crucial step. The original yarn winding action mainly consisted of five movements: tilting the winding tube, pressing the edge, linear displacement, pre-lifting the winding tube to return to center, and returning the winding tube to center. The entire grating production revolves around these five movements, completed through warp and weft winding and layer-by-layer laying.

[0005] However, the existing control system has a significant problem: the controller has a scan cycle for the control program. This system's scan cycle is 4ms. Within this cycle, the PLC needs to sample input signals, execute user programs, and refresh outputs. This scan cycle causes a noticeable pause when the five key yarn winding actions are connected, severely hindering production efficiency.

[0006] Furthermore, the above five actions are executed independently, with no motion correlation between them: the criterion for the completion of the previous action is that all servo axes decelerate to zero speed. After the servo axes have completely stopped, the next action requires the servo axes to be controlled again to complete the acceleration process. This mode has a significant drawback: the cyclic process of "deceleration-stopping-re-acceleration" of the servo axes generates a large amount of invalid time, which seriously prolongs the production cycle of a single yarn winding process and restricts the production efficiency of grid products.

[0007] Taking the production of a single standard grid panel as an example, under the existing system, production takes as long as 60-65 minutes. This not only increases production costs but also makes it difficult to meet rapidly growing market demand. In today's increasingly competitive market, low production efficiency can put companies at a disadvantage, preventing timely product delivery and impacting customer satisfaction and corporate reputation. Therefore, there is an urgent need to improve the existing control system to solve the problem of inconsistent yarn winding action and improve production efficiency.

[0008] Furthermore, the pause during the winding action can easily lead to uneven yarn winding. During the pause between the tilting action of the winding tube and the pressing action, the yarn may become loose or have unstable tension. When the pressing action begins, this can cause uneven winding of the yarn at the pressing position, affecting the structural strength and appearance quality of the grid. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to provide a control system for automatic yarn winding of fiberglass molded grating with high production efficiency and good grating quality.

[0010] To solve the above-mentioned technical problems, the technical solution of the present invention is: an automatic yarn winding control system for molded fiberglass grating based on a continuous interpolation algorithm, the innovation of which lies in: During the automatic yarn winding process, a connection trigger threshold is set near the end of each action. The controller detects the position and state of the yarn winding tube in real time. When the position and state of the yarn winding tube reach the corresponding connection trigger threshold, the controller generates the motion trajectory data of the next action based on a pre-planned continuous interpolation algorithm and sends it to the servo axis that drives the next action. At the same time, the next servo axis is started in advance, so that the next action can be seamlessly connected the moment the previous action is completed. Multi-axis collaboration forms a continuous and smooth motion chain between multiple actions, avoiding the pauses caused by waiting for the controller to scan the cycle, and greatly improving production efficiency and equipment operation stability.

[0011] Furthermore, the single winding process of the yarn tube has 5 actions, namely, the tilting action of the yarn tube, the nodding and pressing action, the warp and weft linear displacement action, the return and pre-lifting action, and the return action. The aforementioned 5 actions are respectively driven by the tilting shaft, the pressing shaft, the displacement shaft, the pre-lifting shaft, and the return shaft.

[0012] Furthermore, the method for planning the motion trajectory is as follows: Based on the motion angle and time requirements of each action, the angle and position coordinates to which the yarn tube should rotate in each interpolation cycle are calculated, thereby planning the motion trajectory of each action and the sequence of coordinate points and corresponding time points on the motion trajectory, and storing the aforementioned motion trajectory data into an array.

[0013] Furthermore, the connection trigger threshold for initiating the nodding and pressing action is: the remaining tilting angle of the tilting action is ≤3~5°, and the time spent on the corresponding remaining tilting angle is 3~4ms; The connection trigger threshold for initiating the latitude and longitude linear displacement action is: the remaining pressure loading amount in the nodding and pressing action is ≤5~10N, and the corresponding remaining pressure loading time is 1~2ms; The trigger threshold for initiating the pre-lifting and return-to-center action is: the remaining displacement during the linear displacement of the latitude and longitude lines is ≤12~18mm, and the corresponding remaining displacement time is 0~0.5s; The trigger threshold for initiating the return-to-center action is: the remaining lifting amount during the return-to-center pre-lifting action is ≤3~8mm, and the corresponding remaining lifting time is 1~2ms.

[0014] The advantages of this invention are: In this control system, the servo axis of the next action is started before the previous action ends, thereby accelerating the servo axis of the next action in advance. This achieves the goal of seamlessly connecting the next action as the previous action is completed, saving the invalid time of the previous servo axis decelerating to zero and then accelerating the next servo axis between adjacent actions. This reduces the total time of a single yarn winding process from the original 4.5 seconds to 2.8 seconds, improves the yarn winding efficiency of the yarn winding tube by about 38%, and shortens the production time of a single grid to 50-55 minutes, improving the production efficiency of a single grid by 10%, resulting in high production efficiency. Attached Figure Description

[0015] Figure 1 This is a continuous interpolation velocity curve of the linear displacement action in the latitude and longitude directions in this invention. Detailed Implementation

[0016] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0017] like Figure 1 The automatic yarn winding control system for molded fiberglass grating based on the continuous interpolation algorithm shown herein sets a connection trigger threshold near the end of each action during the automatic yarn winding process. The controller monitors the position and state of the yarn winding tube in real time. When the position and state of the yarn winding tube reach the corresponding connection trigger threshold, the controller generates motion trajectory data for the next action based on the pre-planned continuous interpolation algorithm and sends it to the servo axis that drives the next action. At the same time, the next servo axis is started in advance, allowing it to accelerate ahead of time. This enables a seamless transition between the next action and the previous action. Multi-axis collaboration creates a continuous and smooth motion chain between multiple actions, avoiding pauses caused by waiting for the controller's scan cycle, and greatly improving production efficiency and equipment stability.

[0018] The method for planning the motion trajectory is as follows: Based on the motion angle and time requirements of each action, the angle and position coordinates to which the yarn tube should rotate in each interpolation cycle are calculated, thereby planning the motion trajectory of each action and the sequence of coordinate points and corresponding time points on the motion trajectory, and storing the aforementioned motion trajectory data into an array.

[0019] The trigger threshold for initiating the nodding and pressing action is: the remaining tilting angle of the tilting action is ≤3~5°, and the time taken for the remaining tilting angle is 3~4ms. The connection trigger threshold for initiating the latitude and longitude linear displacement action is: the remaining pressure loading amount in the nodding and pressing action is ≤5~10N, and the corresponding remaining pressure loading time is 1~2ms; The trigger threshold for initiating the pre-lifting and return-to-center action is: the remaining displacement during the linear displacement of the latitude and longitude lines is ≤12~18mm, and the corresponding remaining displacement time is 0~0.5s; The trigger threshold for initiating the return-to-center action is: the remaining lifting amount during the return-to-center pre-lifting action is ≤3~8mm, and the corresponding remaining lifting time is 1~2ms.

[0020] The single winding process of the yarn tube has 5 actions, namely, tilting action of the yarn tube, nodding and pressing action, warp and weft linear displacement action, return and pre-lifting action, and return action. The aforementioned 5 actions are respectively driven by tilting shaft, pressing shaft, displacement shaft, pre-lifting shaft and return shaft.

[0021] In this control system, the servo axis for the next action is started before the previous action ends, thereby accelerating the servo axis for the next action in advance. This achieves the goal of seamlessly connecting the next action as the previous action is completed, saving the invalid time in the process of the previous servo axis decelerating to zero and then accelerating the next servo axis to running speed between adjacent actions. This reduces the total time of a single yarn winding process from the original 4.5 seconds to 2.8 seconds, improves the yarn winding efficiency of the yarn winding tube by about 38%, and shortens the production time of a single grid to 50-55 minutes, improving the production efficiency of a single grid by 10%, resulting in high production efficiency.

[0022] Example The operating angle change rate of the tilting action of the yarn tube is set to 0.8° / ms, the operating pressure loading rate of the nodding and pressing action is 5N / ms, the operating linear speed of the warp and weft linear displacement action is 120mm / s, the operating height change rate of the return and pre-lifting action is 3mm / ms, and the operating angular speed of the return action is 1.2° / ms, to ensure that the dynamic matching error of each action parameter at the connection node is ≤±5%.

[0023] The process of a single winding of yarn tubes: The controller first starts the tilting shaft, driving the yarn tube to tilt at a speed of 0.8° / ms; When the controller detects that the angle of the yarn tube is about to complete the tilting action (i.e., the remaining tilting angle is ≤3°, and the time taken for the remaining tilting angle is about 3.75ms), the connection trigger threshold of the nodding and pressing action is reached, and the pressing shaft is directly started to accelerate. During this process, the tilting shaft maintains a finishing speed of 0.3° / ms, which is vectored and superimposed with the initial loading speed of the pressing shaft. The pressing shaft will increase the pressure loading rate to 5N / ms when the tilting shaft drives the yarn tube to tilt, so that the nodding pressing action (i.e., the descent action) can be seamlessly connected at the end of the tilting. The nodding and pressing action continues. When the controller detects that the position of the yarn tube is before the nodding and pressing action enters the pressure holding stage (i.e., the remaining pressure loading is ≤8N, corresponding to a pressure loading time of approximately 1.6ms), the connection trigger threshold for the warp and weft linear displacement action is reached, and the displacement axis is directly started at a speed of 30mm / s. 2 The acceleration starts, while the residual pressure of the pressure shaft ensures the yarn adheres; The displacement axis will increase its speed to 120mm / s at the same time as the nodding and pressing action is completed, so that the warp and weft linear displacement action can be seamlessly connected at the same time as the nodding and pressing action is completed. Continuous interpolation of a linear trajectory: Assume the starting coordinates are (x0, y0), the ending coordinates are (x1, y1), and the number of interpolation steps is n. First, calculate the total displacements along the x and y axes: dx = x1 - x0, dy = y1 - y0, and the displacement increments along the x and y axes at each step: dx_step = dx / n, dy_step = dy / n. Then, using a loop, within each interpolation cycle, calculate the coordinates of the current point: x = x0 + i * dx_step, y = y0 + i * dy_step. Send the calculated coordinate values ​​as motion commands to the corresponding servo axes to achieve continuous interpolation of the linear trajectory.

[0024] The warp and weft linear displacement motion continues. When the controller detects that the position of the yarn tube is close to the target position (i.e., the remaining displacement is ≤15mm, corresponding to a remaining motion time of about 0.125s), the connection trigger threshold of the return-to-center pre-lifting action is reached, and the return-to-center pre-lifting action is started directly. At this time, the displacement axis maintains an inertial speed of 20mm / s, which forms a coordinated motion with the initial rising speed of the pre-lifting axis of 2mm / ms. As the linear displacement in the latitude and longitude directions is completed, the rising speed of the pre-lifting shaft will increase to 3mm / ms, thus achieving a seamless connection between the linear displacement in the latitude and longitude directions and the return pre-lifting action. The return-to-center pre-lifting action continues. When the controller detects that the position of the yarn winding tube has reached the set height (i.e., the remaining lifting amount is ≤5mm, corresponding to a remaining motion time of about 1.67ms), the connection trigger threshold of the return-to-center action is reached, and the yarn winding tube return-to-center action is started directly. At this time, the finishing speed of the pre-lifting shaft is 1mm / ms, which forms a spatial trajectory connection with the initial angular velocity of the return-to-center shaft of 0.5° / ms. As the lifting action is completed, the angular velocity of the return axis increases to 1.2° / ms, thus achieving a seamless connection between the return pre-lift action and the return action. Subsequently, the return action is continuously performed at an angular velocity of 1.2° / ms, ultimately achieving precise return of the yarn tube.

[0025] The aforementioned quantitative connection control eliminates the ineffective time of "deceleration-stopping-re-acceleration" between each action in the traditional process, reducing the total time of a single yarn winding process from the traditional 4.5s to 2.8s, and increasing the production efficiency of a single yarn winding process by about 38%, thereby improving the overall production efficiency of the grid.

[0026] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. An automatic yarn winding control system for molded fiberglass grating based on a continuous interpolation algorithm, characterized in that: In the automatic winding process of the winding tube, a connection trigger threshold is set at the end of each action, the position and state of the winding tube are detected in real time by a controller, when the position and state of the winding tube reach the corresponding connection trigger threshold, the controller generates the motion trajectory data of the next action based on the pre-planned continuous interpolation algorithm, and sends it to the servo shaft driving the next action, and at the same time, the next servo shaft is started in advance, so that the next servo shaft accelerates in advance, so that the next action can be seamlessly connected at the moment when the previous action is completed, and the multi-axis cooperation forms a continuous and smooth motion chain between multiple actions.

2. The continuous interpolation algorithm based automatic yarn winding control system for molded glass steel mesh as claimed in claim 1 wherein: The single winding process of the winding tube has 5 actions, which are the dumping action of the winding tube, the nodding and edge pressing action, the straight line displacement action of the warp and weft, the back to normal and pre-lifting action, and the back to normal action, and the above-mentioned 5 actions are respectively driven by the dumping shaft, the edge pressing shaft, the displacement shaft, the pre-lifting shaft and the back to normal shaft.

3. The continuous interpolation algorithm based automatic yarn winding control system for molded glass steel mesh as claimed in claim 1 wherein: The planning method of the motion trajectory is: According to the motion angle and time requirement of each action, the angle and position coordinate of the winding tube in each interpolation period is calculated, so as to plan the motion trajectory of each action, the coordinate point sequence and corresponding time point on the motion trajectory, and store the above-mentioned motion trajectory data in the array.

4. The automatic winding control system for molded glass steel grating based on continuous interpolation algorithm according to claim 2, characterized in that: The connection trigger threshold for starting the nodding and edge pressing action is that the remaining dumping angle of the dumping action is ≤3-5°, and the time spent for the corresponding remaining dumping angle is 3-4ms; The connection trigger threshold for starting the straight line displacement action of the warp and weft is that the remaining pressure loading amount in the nodding and edge pressing action is ≤5-10N, and the time spent for the corresponding remaining pressure loading is 1-2ms; The connection trigger threshold for starting the back to normal and pre-lifting action is that the remaining displacement amount in the straight line displacement action of the warp and weft is ≤12-18mm, and the time spent for the corresponding remaining displacement is 0-0.5s; The connection trigger threshold for starting the back to normal action is that the remaining lifting amount in the back to normal and pre-lifting action is ≤3-8mm, and the time spent for the corresponding remaining lifting is 1-2ms.

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