Intelligent control system and control method for sizing machine based on stay wire sensor

Abstract

The invention discloses an intelligent control system and method for a sizing machine based on a stay wire sensor, relates to the technical field of sizing machine structures, and solves the problems that an existing sizing adjustment process completely depends on manpower, the adjustment precision is low, the stability is poor, and the automation and informatization degree is low. Comprising a longitudinal beam, a trolley assembly and a transmission unit are arranged on the longitudinal beam, the transmission unit drives the trolley assembly to move along the longitudinal beam, the longitudinal beam / trolley assembly is further connected with a displacement detection unit used for sensing the position of the trolley assembly, and the trolley assembly is further connected with a sizing baffle assembly. High-precision automatic positioning of the sizing baffle is achieved through lower modification cost, real-time state sensing, intelligent deviation diagnosis and automatic fault recovery are conveniently achieved, the problem of position drifting of the sizing machine in long-term operation is solved, and the effect of improving the reliability, continuity and intelligent level of the production process is achieved.

Description

Technical Field

[0001] This invention relates to the field of length-keeping machine structure technology, and in particular to an intelligent control system and control method for a length-keeping machine based on a draw wire sensor. Background Technology

[0002] In the hot-rolled bar production line of a steel rolling mill, the sizing machine following the cold shear is a key piece of equipment to ensure the fixed length of the finished product. Its main function is to precisely process the bars that have been initially sheared by the cold shear into finished bars of a fixed length (i.e., "fixed length") that meet customer requirements through conveying, positioning, and secondary shearing.

[0003] Currently, the vast majority of existing steel rolling mills still use mechanical length-setting machines based on a "reducer + drive screw". The length-setting adjustment process relies entirely on manual labor: operators manually jog the reducer from the control panel, estimating the baffle position by observing the faded mechanical scale or using a measuring tape. This traditional method has the following significant drawbacks: Low adjustment accuracy and poor stability: It relies entirely on manual observation and operation, which makes it very easy for visual errors and transmission system gaps (such as screw gaps) to cause unstable length accuracy, resulting in finished product length exceeding tolerance and affecting product quality; Low adjustment efficiency affects production rhythm: Every time the product specification is changed, the operator needs to go back and forth between the control table and the equipment site, repeatedly jogging, observing and measuring, which takes several minutes and seriously restricts the operating efficiency of the production line. Low level of automation and informatization: It cannot be effectively integrated with the production line control system, and the operation data cannot be recorded and traced, making it difficult to achieve lean production and information management; Therefore, there is an urgent need in this field for a technical solution that can achieve precise and automatic adjustment in a low-cost and high-efficiency manner based on the existing reliable mechanical transmission structure. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent control system and control method for a length-fixing machine based on a wire sensor. This system achieves high-precision automatic positioning of the length-fixing baffle at a lower modification cost, and integrates real-time status perception, intelligent deviation diagnosis, and automatic fault recovery. It solves the position drift problem of the length-fixing machine during long-term operation and improves the reliability, continuity, and intelligence of the production process.

[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A length-fixing machine intelligent control system based on a wire sensor includes a longitudinal beam, on which a trolley assembly and a transmission unit are mounted. The transmission unit drives the trolley assembly to move along the longitudinal beam. A displacement detection unit for sensing the position of the trolley assembly is also connected to the longitudinal beam / trolley assembly. A length-fixing baffle assembly is also connected to the trolley assembly.

[0006] Furthermore, the displacement detection unit includes a wire encoder.

[0007] Furthermore, the fixed-length baffle assembly is provided in several parts, which are respectively connected to different positions of the trolley assembly.

[0008] Furthermore, the fixed-length baffle assembly includes a fixed rod and a telescopic drive component hinged to the bottom of the trolley assembly. The outer ends of the telescopic drive component and the fixed rod are hinged to each other, and the outer end of the fixed rod is connected to the fixed-length baffle.

[0009] This application also discloses a control method, comprising the following steps. Step S10: Set the required length for production and obtain the target position P_target for the movement of the trolley unit. In step S20, the transmission unit drives the trolley assembly to move towards the target position P_target. Step S30: The displacement detection unit senses the current position P_current of the trolley component and calculates the position error e=|P_target-P_current|. When the position error e≤ the positioning accuracy tolerance, the transmission unit stops working. Step S40, positioning complete.

[0010] Furthermore, it also includes, Step S50: After completing the positioning, continuous monitoring begins. The displacement detection unit periodically senses the current position P_current of the trolley component and calculates the process deviation e_process=|P_current-P_target|, and responds according to the process deviation e_process.

[0011] Furthermore, when the process deviation e_process > the preset process fault alarm threshold, the cold shear machine is controlled to pause shearing.

[0012] Furthermore, when the process deviation e_process > the preset process fault alarm threshold, steps S20 to S40 are executed to complete the repositioning.

[0013] Furthermore, if the process deviation e_process ≤ the preset process monitoring early warning threshold, return to step S50 to continue monitoring.

[0014] Further, when the process monitoring warning threshold <e_process ≤ the process fault alarm threshold, a warning prompt is issued, but production is still maintained, and the process returns to step S50 to continue monitoring.

[0015] In summary, the present invention has the following beneficial effects: It realizes the leap from "open-loop control" to "full-life-cycle closed-loop intelligent control". It not only solves the automation problem of initial positioning, but more innovatively introduces continuous monitoring and intelligent maintenance of the operating state of the equipment, filling the technical gap in this field. It significantly improves the reliability of the system and the ability to guarantee product quality: Through the closed-loop mechanism of "real-time monitoring - warning - alarm - automatic recovery", it can intervene and self-heal before batch waste products are caused by position deviation, transforming passive fault handling into active health management, greatly reducing quality risks and unplanned downtime. It maintains the outstanding advantages of low cost and easy transformation, realizes the intelligent control of the equipment, has a small transformation cost, a short implementation cycle, and wide applicability, and has extremely high engineering application and promotion value. It enhances the intelligence and informatization level of the production line. The system can record all positioning, deviation, alarm, and recovery event data, providing data support for equipment status analysis, preventive maintenance, and production process optimization, which is in line with the development direction of intelligent manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic structural diagram of an intelligent control system for a fixed-length cutting machine based on a wire-pulling sensor according to the present invention. Figure 2 is Figure 1 a schematic diagram from another perspective; Figure 3 It is a schematic flowchart of a part of a control method according to the present invention.

[0017] In the figure, 1, longitudinal beam; 11, connecting beam; 12, column; 2, trolley assembly; 21, scale; 3, transmission unit; 4, displacement detection unit; 5, fixed-length cutting baffle assembly; 51, fixed rod; 52, telescopic driving member. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] The following further describes the specific embodiments of the present invention with reference to the drawings. This embodiment does not constitute a limitation to the present invention. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the protection scope of this application.

[0019] An intelligent control system for a fixed-length cutting machine based on a wire-pulling sensor, as Figure 1 and Figure 2As shown, it includes a longitudinal beam 1. In this embodiment, two pairs of connecting beams 11 are connected to both sides of the longitudinal beam 1. The connecting beams 11 are fixed to the column 12. The column 12 is fixed or placed on the ground to realize the fixing and placement of the longitudinal beam 1. A conveying device is set below the longitudinal beam 1 to convey the bar material. The longitudinal beam 1 is equipped with a trolley assembly 2 and a transmission unit 3. A track can be connected to the longitudinal beam 1 along its length. The trolley assembly 2 is connected to several rollers, and the trolley assembly 2 can be adjusted back and forth along the longitudinal beam 1 by sliding the rollers in the track. The transmission unit 3 drives the trolley assembly 2 to move along the longitudinal beam 1. In this embodiment, the transmission unit 3 includes a motor and a lead screw. The lead screw is rotatably connected to the longitudinal beam 1. The motor drives the lead screw to rotate through a transmission structure such as a reducer. A slider is connected to the lead screw and is fixedly connected to the trolley assembly 2 on both sides of the slider to realize the driving movement of the trolley assembly 2. The slider can also be connected to a guide assembly to further realize guidance.

[0020] like Figure 1 As shown, a displacement detection unit 4 for sensing the position of the trolley assembly 2 is also connected to the longitudinal beam 1. In this embodiment, in order to improve the sensing accuracy, the displacement detection unit 4 includes a pull-wire encoder. An L-shaped steel mounting bracket is fixed on the longitudinal beam 1. Its vertical plate is fixed to the longitudinal beam 1 by bolts, and its horizontal plate is fixed to the housing of the pull-wire encoder by clamps or other means. The pull end of the pull wire of the pull-wire encoder is connected to the connecting lug pre-welded on the trolley assembly 2 or the lead screw slider through a universal ball joint connector with an anti-loosening nut to realize pull-wire distance measurement. It can be replaced with other contact or non-contact distance sensing components. In this embodiment, an industrial PLC is used as the core controller. The pull-wire sensor (output signal is 4-20mA analog or SSI digital signal) is connected to the analog / high-speed counting module of the PLC. The PLC controls the start, stop and direction of the geared motor driver through the digital output module to complete the forward and reverse rotation of the motor, so as to adjust the front and rear positions of the trolley component 2 according to the production specifications. The PLC can also be connected to the industrial control computer (human-machine interface) in the central control room through industrial Ethernet.

[0021] like Figure 1 As shown, a fixed-length baffle assembly 5 is also connected below the trolley assembly 2. There are several fixed-length baffle assemblies 5, which are respectively connected to different positions of the trolley assembly 2. In this embodiment, they are evenly distributed, and the spacing is equal to or less than the stroke of the transmission unit 3, so as to cooperate with the adjustment of the fixed-length baffle assembly 5 and the transmission unit 3 at different positions, realize the baffle function at different positions, and improve the versatility of the equipment. The fixed-length baffle assembly 5 includes a fixed rod 51 hinged to the bottom of the trolley assembly 2 and a telescopic drive component 52. The telescopic drive component 52 can be a cylinder or an electric cylinder, etc. The outer ends of the telescopic drive component 52 and the fixed rod 51 are hinged to each other. The drive rod is rotated to the vertical downward position to perform baffle operation (baffle position) or to the oblique upward position away from the baffle position. The outer end of the fixed rod 51 is connected to the fixed-length baffle. The fixed-length baffle is set in the direction of bar conveying to realize that one end of the bar is blocked at the corresponding position (baffle position) for screening according to the length of the bar. For example, a lifting pressure plate is set at a preset position to press down the bar that is longer than the corresponding length. Then the fixed-length baffle moves away (obliquely moves away from the baffle position) to let the bar that is not long enough to be conveyed away. Finally, the lifting pressure plate rises to let the bar that is longer than the corresponding length be conveyed away.

[0022] This application also discloses a control method, such as Figure 3 As shown, it includes the following steps: Step S10, Initial parameter setting: Input the required length L (e.g., 12000mm) on the industrial computer human-machine interface. The system can preset multiple product specifications and realize one-click calling. Step S11, Target position calculation: In some embodiments, L is also compensated. After the PLC receives the length L, it calls the internal parameter table and calculates the target position P_target according to the formula P_target=L–Δ, where Δ is the fixed compensation value between the system mechanical zero position and the shear zero position. The target position P_target of the trolley unit is obtained by calibration and stored. Step S20, Automatic Positioning Execution: The PLC sends a positive start command to the geared motor driver to control the motor to work. The transmission unit drives the trolley assembly to move towards the target position P_target via the lead screw. Step S30: The PLC reads the current position P_current of the trolley component sensed by the displacement detection unit in real time; Step S31, Positioning judgment: Calculate the position error e=|P_target-P_current|. When the position error e≤ the positioning accuracy tolerance δ1 (for example, set to 2mm), the transmission unit stops working and the positioning is completed; otherwise, return to step S30 to continue moving. Step S40, Positioning Complete: After positioning is complete, the PLC issues a stop command, the motor stops, and the baffle stops precisely at position P_target. The system displays "Positioning Complete" on the human-machine interface and stores P_target; Step S50, process monitoring loop: After positioning is completed, enter continuous monitoring mode. The PLC reads the current position P_current of the trolley component at a fixed period (e.g., every second). Step S51, Deviation Calculation and Judgment: Calculate the process deviation e_process = |P_current - P_target|, and perform corresponding grading according to the process deviation e_process. If e_process ≤ δ2 (δ2 is the process monitoring warning threshold, for example, 3 mm), the system status is normal, and return to step S50 to continue monitoring. If δ2 < e_process ≤ δ3 (δ1 ≤ δ2 < δ3, δ3 is the process fault alarm threshold, for example, 5 mm), the system issues a yellow warning prompt on the human-machine interface, records the warning event, but still maintains production, and return to step S50 to continue monitoring. If e_process > δ3, the system determines that a fault has occurred, and immediately execute step S52. Step S52, Fault Alarm and Safety Confirmation: The PLC immediately controls the cold shear to pause shearing (or issues an interlock request), pops up a red alarm window on the human-machine interface and triggers the on-site sound and light alarm. Meanwhile, the system waits to receive the "Allow Automatic Recovery" signal, which can be set to be automatically generated (such as when the shear is in a non-shearing cycle) or issued after being manually confirmed by the operator to ensure the absolute safety of the recovery process. Once the "Allow Automatic Recovery" signal is received, the PLC automatically calls and re-executes the automatic positioning process from step S20 to step S40 to accurately reset the baffle to P_target; after the reset is completed, the alarm is解除, the system records this fault and recovery event in the log, and automatically returns to step S50 to continue process monitoring.

[0023] In some embodiments, a trend analysis algorithm is further added to analyze the dynamic trend of the position deviation e_process; if it is identified that the deviation continuously increases unidirectionally within a set time, even if its instantaneous value does not exceed the alarm threshold δ3, the system can also generate a predictive maintenance alarm in advance, so as to achieve early warning of potential faults such as mechanical connection looseness, and upgrade the maintenance mode to the predictive maintenance level.

[0024] The above is only a preferred embodiment of the present invention and is not used to limit the present invention. Those skilled in the art can make various modifications or equivalent replacements to the present invention within the essence and protection scope of the present invention, and such modifications or equivalent replacements should also be regarded as falling within the protection scope of the technical solution of the present invention.

Claims

1. An intelligent control system for a length-keeping machine based on a draw-wire sensor, characterized in that: It includes a longitudinal beam, on which a trolley assembly and a transmission unit are provided. The transmission unit drives the trolley assembly to move along the longitudinal beam. A displacement detection unit for sensing the position of the trolley assembly is also connected to the longitudinal beam / trolley assembly. A fixed-length baffle assembly is also connected to the trolley assembly.

2. The intelligent control system for a length-keeping machine based on a draw wire sensor according to claim 1, characterized in that: The displacement detection unit includes a wire-drawing encoder.

3. The intelligent control system for a length-keeping machine based on a draw wire sensor according to claim 1, characterized in that: A number of the fixed-length baffle assemblies are provided and are respectively connected to different positions of the trolley assembly.

4. The intelligent control system for a length-keeping machine based on a draw wire sensor according to claim 1 or 3, characterized in that: The fixed-length baffle assembly includes a fixed rod hinged below the trolley assembly and a telescopic driving member. The telescopic driving member and the outer end of the fixed rod are hinged to each other, and the outer end of the fixed rod is connected to a fixed-length baffle.

5. A control method, employing the intelligent control system for a length-keeping machine based on a draw-wire sensor as described in claim 1, characterized in that: It includes the following steps Step S10: Set the fixed length required for production to obtain the target position P_target of the trolley unit to move. Step S20: The transmission unit drives the trolley assembly to move towards the target position P_target. Step S30: The displacement detection unit senses the current position P_current of the trolley assembly, calculates the position error e = |P_target - P_current|. When the position error e ≤ the positioning accuracy tolerance, the transmission unit stops working. Step S40: The positioning is completed.

6. The control method according to claim 5, characterized in that: It also includes Step S50: After the positioning is completed, enter continuous monitoring. The displacement detection unit periodically senses the current position P_current of the trolley assembly, calculates the process deviation e_process = |P_current - P_target|, and makes a response according to the process deviation e_process.

7. The control method according to claim 6, characterized in that: When the process deviation e_process > the preset process fault alarm threshold, control the cold shear to pause shearing.

8. A control method according to claim 6 or 7, characterized in that: When the process deviation e_process > the preset process fault alarm threshold, execute steps S20 to S40 to complete repositioning.

9. The control method according to claim 6, characterized in that: When the process deviation e_process ≤ the preset process monitoring warning threshold, return to step S50 to continue monitoring.

10. A control method according to claim 6 or 9, characterized in that: When the process monitoring warning threshold < e_process ≤ the process fault alarm threshold, issue a warning prompt, but still maintain production, and return to step S50 to continue monitoring.

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