Gantry shear lifting control method and device based on material pushing thickness detection

Abstract

The invention discloses a gantry shear lifting control method and device based on material pushing thickness detection, and relates to the technical field of waste metal recycling and processing equipment. The method comprises the steps that before materials are transferred to a material pressing station and a material shearing station, thickness parameters of a to-be-treated material pile are obtained; synchronously determining a first target lifting height of a material pressing execution mechanism and a second target lifting height of a material shearing execution mechanism based on the thickness parameter; and controlling the material pressing execution mechanism and the material shearing execution mechanism to lift, monitoring the heights of the material pressing execution mechanism and the material shearing execution mechanism relative to the bearing surface of the corresponding working platform in real time in the lifting process, and controlling the corresponding execution mechanisms to stop lifting when the monitored heights respectively reach a first target lifting height and a second target lifting height. According to the invention, through prospective thickness detection and synchronous height setting of the double moving parts, dynamic optimization of the lifting height of material pressing and material shearing is realized, the idle stroke is effectively shortened, and the production efficiency of the gantry shear is remarkably improved.

Description

Technical Field

[0001] This invention belongs to the technical field of waste metal recycling and processing equipment, and particularly relates to a gantry shear lifting control method and device based on material pushing thickness detection. Background Technology

[0002] Gantry shears are key pieces of equipment used for shearing large scrap metal. Their automated continuous operation process typically includes: pushing the material to the workstation (pushing), clamping the material (pressing), and shearing the material (shearing). To increase production capacity, the equipment operates continuously in a basic cycle of "pushing-pressing-shearing".

[0003] Currently, most gantry shears use a fixed stroke control method, meaning the lifting height of both the pressure block and the shearing blade holder is a preset fixed value. This fixed value must be set according to the equipment's maximum allowable processing thickness to ensure safe passage of the material under any circumstances, avoiding the risk of blade collision. However, the actual thickness of the scrap metal piles being processed is random and usually far below the equipment's maximum capacity. When the material thickness is small, the pressing and lifting of the pressure block, and the cutting and lifting of the shearing blade holder, will generate a large amount of ineffective idle strokes. These strokes do not perform effective work but significantly prolong the single-cycle operation time, becoming a major bottleneck restricting the improvement of production efficiency.

[0004] To address the efficiency issues caused by fixed strokes, some dynamic adjustment schemes have emerged in the prior art. For example, patent document CN114905084A proposes a scheme: photoelectric distance sensors are installed above the pressure head and the shear head, respectively. By detecting the actual height of the pressure head after the pressure action (pressure height) and adding a safety margin (Δ), the lifting height of the shear head is dynamically set (lifting height = pressure height + Δ). This scheme reduces the idle stroke time of the shearing process to a certain extent by adjusting the lifting height of the shear head in real time.

[0005] However, such existing dynamic adjustment schemes still have significant limitations and fail to fundamentally achieve cycle time optimization across the entire process:

[0006] First, its optimization target is singular, only adjusting the lifting height of the scissor head, without simultaneously optimizing the lifting height of the pressing block, so the ineffective empty stroke in the pressing process still exists;

[0007] Second, its control logic is "post-event adjustment". It can only obtain height information and calculate the set value after the pressing action is completed. It cannot perform forward-looking optimal planning before the pressing and shearing actions begin, and the response is delayed.

[0008] Third, its control basis is the "height after compaction". This height is the state of the material after it is compacted. For materials that are significantly deformed or loose during compaction, there may be a large difference between the material and the initial push thickness. The lifting height set based on this may not be optimal, and there is still room for further compression.

[0009] In summary, existing technologies—whether traditional fixed-stroke control or dynamic adjustment based on post-pressing detection—fail to accurately predict material thickness at the start of the work cycle and accordingly optimize the lifting stroke of the two key stages of pressing and shearing in a synchronous and forward-looking manner. Therefore, developing a control method that can completely reduce ineffective idle strokes and comprehensively improve the production cycle time of gantry shears remains a pressing technical problem in this field. Summary of the Invention

[0010] In view of the above-mentioned defects in the prior art, the purpose of the present invention is to provide a gantry shear lifting control method and device based on material thickness detection, so as to solve the technical problems of long idle stroke and slow production cycle caused by the inability to predict the material thickness at the beginning of the operation and perform synchronous forward control.

[0011] This invention solves the above-mentioned technical problems through the following technical solution: a gantry shear lifting control method based on material pusher thickness detection, comprising:

[0012] Before the material is transferred to the pressing station and the shearing station of the gantry shear, the thickness parameters of the material to be processed in its original stacked state are obtained at the pushing station.

[0013] Based on the thickness parameter, the first target lifting height of the pressing actuator and the second target lifting height of the shearing actuator are determined simultaneously; wherein, the determination of the first target lifting height and the second target lifting height are based on the thickness parameter and superimposed with the corresponding preset safety value;

[0014] The material pressing actuator is controlled to lift, and its height relative to the bearing surface of the work platform of the material pressing station is monitored in real time during the lifting process. When the monitored height reaches the first target lifting height, the material pressing actuator is controlled to stop lifting.

[0015] The shearing actuator is controlled to lift, and its height relative to the working platform bearing surface of the shearing station is monitored in real time during the lifting process. When the monitored height reaches the second target lifting height, the shearing actuator is controlled to stop lifting.

[0016] This invention optimizes the entire gantry shear operation cycle by acquiring thickness parameters before the material is transferred to the pressing and shearing stations and simultaneously determining the target lifting height of both the pressing and shearing actuators. Compared to the traditional fixed-height mode, this invention dynamically adjusts the lifting height of the pressing block (pressing actuator) and the shearing blade holder (shearing actuator) to the minimum necessary value based on the current material pile thickness, thereby minimizing the ineffective idle strokes in both stages. This simultaneous elimination of idle strokes in both pressing and shearing produces a synergistic effect of "1+1>2," significantly shortening the single operation cycle time at the system level, fundamentally accelerating the production cycle, and improving overall production efficiency.

[0017] To address the limitation of existing technologies that only optimize the shear blade lifting height while neglecting the blanking stroke of the pressing block, this invention proposes a control logic that synchronously determines the lifting height of two targets based on the same thickness parameter. This ensures that the actions of both the pressing and shearing actuators are planned in advance, achieving coordinated and independent precise control of the two moving parts. This design fills the gap in the optimization of the pressing stage in existing technologies, solves the long-standing problem of localized optimization, and allows the gantry shear's equipment capacity to be fully and evenly released. This represents a significant improvement and transcendence of existing technical solutions.

[0018] This invention sets the thickness detection point at the feeding station and makes decisions based on the original material accumulation state, which is a typical example of feedforward control. This is fundamentally different from the feedback control mode of existing technologies, which can only perform detection and adjustment after the "pressing action is completed". Feedforward control enables the system to calculate and set the optimal lifting height before the pressing and shearing actions begin, completely eliminating control lag caused by waiting for detection results. This not only further reduces cycle time but also makes the entire control process smoother and faster-responding, providing a reliable guarantee for high-cycle continuous production.

[0019] This invention uses the original stacked thickness of the material as the direct basis for control. This parameter is intuitive, stable, and unaffected by the compression deformation of the material during the compaction process. In contrast, schemes that adjust based on the "height after compaction" require setting values ​​that compensate for the uncertainty of compaction deformation, resulting in a conservative safety margin. The control logic based on the original thickness is more direct and precise, allowing the superimposed preset safety value to be set only for mechanical clearances and minimal safety margins. This provides a technical basis for achieving more extreme lifting height compression and pursuing the theoretically shortest empty stroke, which is the potential advantage of this invention in terms of optimization depth.

[0020] Further, obtaining the thickness parameters of the material pile in its original stacking state includes:

[0021] A series of distance measurements between the material pile surface and the first ranging sensor are obtained.

[0022] Find the minimum value from the series of distance measurements;

[0023] The thickness parameter is obtained by subtracting the minimum value from the preset fixed distance between the measurement reference surface of the first ranging sensor and the bearing surface of the working platform.

[0024] By employing a minimum value algorithm (taking the minimum value from a series of distance measurements) combined with a calculation method based on a fixed geometric reference (installation height minus this value), the maximum thickness of the material pile can be obtained accurately and reliably. The minimum value corresponds to the highest point of the material, thus ensuring that the measured thickness parameter is sufficient to cover the entire material pile, providing an accurate basis for safe lifting. At the same time, calculations based on a fixed installation height and the bearing surface of the working platform make the measurement system independent of the deformation of the host structure, significantly improving the stability and repeatability of thickness detection, and laying a reliable data foundation for subsequent dynamic height control.

[0025] Furthermore, a series of distance measurements are acquired through the first ranging sensor, including any of the following methods:

[0026] Method 1: Move a single first ranging sensor along a direction parallel to the width of the material pusher hopper, and continuously measure during the movement;

[0027] Method 2: Set multiple or continuously linearly arranged ranging sensors as the first ranging sensor and perform synchronous measurements.

[0028] By providing two optional thickness detection implementation methods (mobile scanning or fixed array), the system is given a high degree of flexibility and adaptability: Method 1 (mobile measurement) achieves full-width scanning of the hopper without blind spots at a lower cost, suitable for scenarios where equipment modification budgets are sensitive or where the hopper width is large; Method 2 (synchronous measurement) acquires full-line data at once through the sensor array, completely eliminating the time required for sensor movement, further reducing the time consumption of the detection process, and providing a hardware foundation for pursuing the ultimate production cycle. Both methods can reliably obtain the maximum thickness, and users can flexibly choose according to production rhythm, cost, and maintenance needs, improving the practicality and scalability of the invention.

[0029] Furthermore, the first target lifting height is the set lifting height of the pressure block, and its specific calculation formula is as follows:

[0030] H ps =H th +α;

[0031] Among them, H ps Indicates the set lifting height of the pressure block; Hth This represents the thickness parameter; α represents the preset minimum safety clearance for the material.

[0032] The second target lifting height is the set lifting height of the shearing moving blade holder, and its specific calculation formula is as follows:

[0033] H cm =H th +β;

[0034] Among them, H cm β indicates the set lifting height of the shearing moving blade holder; β indicates the preset minimum safety clearance for shearing.

[0035] By using the same original thickness parameter (H) th The independent linear calculation formula provides a highly adaptable and decoupled control strategy for the two actuators of pressing and shearing: the formula structure is simple and direct, ensuring the system's fast response and high reliability; at the same time, the independently adjustable preset safety clearances (α and β) enable the system to precisely match the different mechanical clearances and safety requirements of the pressing and shearing processes respectively. Under the premise of absolutely ensuring safety (anti-collision blade), personalized and minimized lifting height settings are achieved for each actuator, thereby compressing their respective ineffective idle strokes to the theoretical limit and contributing to the maximum improvement of the overall production cycle.

[0036] Furthermore, real-time monitoring of the height of the material pressing actuator relative to the bearing surface of the working platform of the material pressing station includes:

[0037] A second distance sensor installed above the pressing station directly and in real time measures the first real-time distance between the lower surface of the pressing actuator and the pressing platform; when the first real-time distance is equal to the first target lifting height, it is determined that the monitored height has reached the first target lifting height.

[0038] Real-time monitoring of the height of the shearing actuator relative to the bearing surface of the working platform of the shearing station includes:

[0039] A third distance sensor installed above the shearing station directly measures the second real-time distance between the lower surface of the shearing actuator and the shearing platform; when the second real-time distance is equal to the second target lifting height, it is determined that the monitored height has reached the second target lifting height.

[0040] By employing a ranging device to directly measure the real-time distance between the lower surface of the actuator and the corresponding working platform bearing surface, high-precision, direct-feedback closed-loop control of the lifting process is achieved. Using the physical platform as a fixed reference for measurement effectively avoids the cumulative errors that may be introduced by using variable structures such as the main frame as a reference, ensuring the long-term stability and reliability of height control. Direct comparison between the real-time distance and the target lifting height enables rapid control response and direct judgment, greatly improving the accuracy of the lifting stop position. This reliably translates the dynamically set lifting height into actual action, ensuring the accurate realization of the idle stroke compression effect in actual production, while also enhancing the safety of equipment operation.

[0041] Furthermore, real-time monitoring of the height of the material pressing actuator relative to the bearing surface of the working platform of the material pressing station includes:

[0042] The first measurement distance value between the second distance sensor and the designated reference surface on the material pressing actuator is measured in real time using the second distance sensor.

[0043] Based on the first measured distance value, the preset installation height of the second ranging sensor, and the known structural height of the pressing actuator, the first real-time clearance distance between the lower surface of the pressing actuator and the bearing surface of the working platform is calculated; wherein, the first real-time clearance distance = (preset installation height of the second ranging sensor - known structural height of the pressing actuator) - first measured distance value;

[0044] Real-time monitoring of the height of the shearing actuator relative to the bearing surface of the working platform of the shearing station includes:

[0045] The second measurement distance value between the third distance sensor and the designated reference surface on the shearing actuator is measured in real time using the third distance sensor.

[0046] Based on the second measured distance value, the preset installation height of the third ranging sensor, and the known structural height of the shearing actuator, the second real-time clearance distance between the lower surface of the shearing actuator and the bearing surface of the working platform is calculated; wherein, the second real-time clearance distance = (preset installation height of the third ranging sensor - known structural height of the shearing actuator) - second measured distance value.

[0047] By employing indirect measurement and fixed parameter compensation calculation, a highly robust and adaptable preferred implementation scheme for lifting height monitoring is provided. By specifying a reference surface on the measuring actuator and performing real-time conversion between the preset installation height and the actuator's own height, the sensor can be fixedly installed in a cleaner and more stable location. This avoids interference or failure caused by oil, debris, or spatial obstructions that could result from direct ranging of the moving lower surface, significantly improving the system's long-term operational reliability and environmental adaptability. Simultaneously, this calculation model firmly anchors the control benchmark to the working platform's bearing surface, ensuring that control accuracy is unaffected by factors such as frame deformation, providing a solid guarantee for achieving safe and accurate closed-loop stopping.

[0048] Furthermore, when initiating an automated job, the method executes any of the following processes:

[0049] Process 1: Perform a pressing and shearing operation without pushing the material. During this process, the thickness parameter is acquired and the first target lifting height and the second target lifting height are determined accordingly. After the current shearing operation is completed, the pressing and shearing actuators are controlled to lift, and their heights are monitored in real time until they reach the corresponding target lifting heights determined based on the thickness parameter. Then, the process jumps to the continuous automatic operation process.

[0050] Step 2: First, raise the pressing and shearing actuators to their highest positions. During this process or after they reach their positions, acquire the thickness parameters and determine the first and second target lifting heights accordingly. Then, execute a complete operation including pushing, pressing, and shearing. After the current shearing operation is completed, control the pressing and shearing actuators to lift, while monitoring their heights in real time, until they reach the corresponding target lifting heights determined based on the thickness parameters, and then stop. Then, switch to the continuous automatic operation process.

[0051] By offering two optional startup initialization processes, the system possesses a high degree of operational flexibility and adaptability to various operating conditions: Process 1 completes parameter learning synchronously during "idle operation," achieving a seamless connection between production preparation and first-piece work, particularly suitable for resuming operations after short pauses in continuous production; Process 2 completes parameter initialization in an absolutely safe, highest-level state, making it more suitable for cold starts or safe operations after changing material batches. Both processes ensure that the system can quickly, safely, and accurately complete the self-learning and setting of core control parameters (thickness and target lifting height) before entering an efficient and continuous automatic operation cycle, significantly reducing the equipment's reliance on operator experience and improving the equipment's rapid readiness and overall intelligence level under different operating conditions.

[0052] Furthermore, the continuous automated operation process includes the following steps, which are executed periodically:

[0053] Step A1: Perform the material pushing, pressing, and shearing operations;

[0054] Step A2: After the shearing operation is completed, control the pressing mechanism and the shearing mechanism to lift, and monitor their height in real time until the monitored heights reach the first target lifting height and the second target lifting height determined in the current cycle, respectively, and then stop.

[0055] Step A3: When the pressing actuator stops lifting, re-execute the steps of obtaining the thickness parameters of the material pile to be processed and determining the target lifting height, and then return to step A1.

[0056] By constructing a closed-loop adaptive cycle process of "execution-lifting stop-pre-learning for the next cycle", seamless connection and continuous iteration of production and optimization are achieved: at the end of the lifting action of each work cycle (step A3), the system uses the interval of the material pressing actuator to complete the measurement of the thickness of the next batch of materials to be processed and the calculation of the target lifting height in parallel, so that the production cycle is not interrupted due to parameter learning; this design deeply integrates forward control (pre-calculation for the next cycle) and real-time closed-loop control (precisely stopping at the target lifting height of the current cycle), ensuring that the gantry shear can always maintain the optimal lifting stroke based on the latest working conditions in fully automatic continuous operation, thereby continuously transforming the effect of dynamic optimization into stable production efficiency improvement, realizing true intelligent and adaptive production.

[0057] Based on the same concept, the present invention also provides a gantry shear lifting control device based on material pusher thickness detection, comprising:

[0058] The thickness parameter detection module is located at the pushing station of the gantry shear and is used to measure and output the thickness parameter of the material pile to be processed before the material is transferred to the pressing station and the cutting station of the gantry shear.

[0059] The first height detection module is located at the pressing station and is used to detect the height of the pressing actuator relative to the bearing surface of the working platform of the pressing station in real time during the lifting process of the pressing actuator, and generate the corresponding first height detection signal.

[0060] The second height detection module is located at the shearing station and is used to detect the height of the shearing actuator relative to the working platform bearing surface of the shearing station in real time during the lifting process of the shearing actuator, and generate the corresponding second height detection signal.

[0061] Controller, used for:

[0062] Based on the received thickness parameters, the first target lifting height of the pressing actuator and the second target lifting height of the shearing actuator are simultaneously determined; wherein, the determination of the first target lifting height and the second target lifting height are based on the thickness parameters and superimposed with corresponding preset safety values;

[0063] During the lifting process of the material pressing actuator, it is determined whether the real-time height of the material pressing actuator has reached the first target lifting height based on the received first height detection signal, and if the determination is yes, a first stop lifting command is issued to the material pressing actuator;

[0064] During the lifting process of the shearing actuator, the real-time height of the shearing actuator is determined based on the received second height detection signal to determine whether the second target lifting height has been reached, and if the determination is yes, a second stop lifting command is issued to the shearing actuator;

[0065] The material pressing actuator is connected to the controller for performing material pressing operations, and performs lifting actions in response to the control signal of the controller and stops lifting in response to the first stop lifting command;

[0066] The shearing actuator is connected to the controller for performing shearing operations, and performs lifting actions in response to the control signal of the controller and stops lifting in response to the second stop lifting command.

[0067] This invention's device incorporates a core design that uses a thickness parameter detection module to pre-measure materials at the feeding station and a controller to synchronously calculate the dual-target lifting height, thus solidifying the concept of "proactive dynamic optimization" into the hardware system. Under the real-time feedback from their respective height detection modules and the precise commands from the controller, the pressing and shearing mechanisms stop at the minimum necessary height calculated based on the current material thickness with each lift. This hardware system's end-to-end coordination from perception and decision-making to execution ensures that ineffective idle travel in both the pressing and shearing stages is synchronously and reliably eliminated physically, thereby transforming the improvement of production efficiency from a theoretical method into stable and repeatable inherent equipment performance.

[0068] The device of this invention explicitly sets up independent first height detection modules and second height detection modules, and endows the controller with the ability to process the two signals and issue independent commands respectively. This hardware architecture completely solves the problem of existing technologies that only optimize the shearing actuator but lack closed-loop control of the pressing height at the hardware level. It enables both the pressing and shearing actuators to accurately stop according to their real-time positions, realizing true independent collaborative optimization of the two moving parts, filling the functional gap of existing equipment at the hardware control level, and fully releasing the potential of the equipment.

[0069] This invention places the critical thickness detection module at the front end and fixes it at the material feeding station, forming a deterministic hardware data flow of "detection first, operation later". This layout enables feedforward control, allowing the controller to complete all calculations before the material arrives at the pressing and shearing stations, completely eliminating the hardware timing delay of existing technologies that must wait for pressing to complete before detection and calculation can begin. The response speed of the entire system is no longer limited by the completion of a single action, thus providing a solid hardware foundation for pursuing extreme production cycles and enabling efficient and smooth continuous operation.

[0070] In this invention, all height detection modules use the bearing surface of the corresponding work platform as the physical measurement reference. This unified reference design, directly linked to the working plane, avoids systematic errors introduced by using structures such as the main frame, which may deform due to load or temperature, as the reference. Combined with the direct algorithm in the controller based on preset safety values, this hardware system forms a highly stable and highly repeatable measurement-control closed loop. This not only ensures that dynamic optimization effects are accurately implemented but also significantly improves the control reliability and safety of the equipment under different working conditions and long-term operation, while reducing maintenance and calibration costs.

[0071] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0072] This invention dynamically and synchronously sets the lifting height of both pressing and shearing based on the original thickness of the material, compressing the ineffective idle stroke of both to the theoretical minimum. This systematically shortens the operation cycle time and significantly improves the production cycle time and overall efficiency of the equipment. It overcomes the limitations of existing technologies that only optimize a single link (shearing), and performs forward-looking integrated height planning for the pressing and shearing actuators, solving the long-standing efficiency bottleneck of "unoptimized pressing idle stroke" and realizing the full release of equipment capacity. It adopts a feedforward control strategy that detects the thickness in advance during the pushing stage, replacing the lagging method of "adjusting after pressing" in the existing technology, resulting in a more timely response. At the same time, it uses the original loose thickness of the material as a direct and accurate control basis, avoiding calculation errors caused by material compression deformation, and providing the possibility for more extreme stroke optimization.

[0073] This invention provides highly closed-loop control, multiple thickness detection methods, and a flexible start-up process, ensuring precise and safe control and enabling the equipment to adapt to different working conditions and production rhythms, thereby improving the equipment's intelligence level and ease of operation. Attached Figure Description

[0074] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only one embodiment of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0075] Figure 1 This is a schematic diagram of the gantry shear lifting control device in an embodiment of the present invention;

[0076] Figure 2 This is a schematic diagram of the ranging principle in an embodiment of the present invention;

[0077] Figure 3 This is a schematic diagram of the installation of the first ranging sensor in an embodiment of the present invention;

[0078] Figure 4 This is a flowchart of the gantry shear lifting control method based on material pusher thickness detection in an embodiment of the present invention.

[0079] Explanation of reference numerals in the attached drawings: 1-Working platform, 11-Fixed blade device, 2-Shearing actuator, 21-Second hydraulic cylinder, 22-Moving blade holder, 23-Moving blade, 24-Third distance sensor, 3-Pressure actuator, 31-First hydraulic cylinder, 32-Pressure block, 4-Pushing hopper, 41-Pushing block, 5-First distance sensor. Detailed Implementation

[0080] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0081] The technical solution of the present invention will be described in detail below with reference to specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments.

[0082] Example 1

[0083] This embodiment provides a gantry shear lifting control method based on material pushing thickness detection, aiming to solve the problems of long idle stroke and slow production cycle caused by the fixed lifting height of pressing and shearing in the prior art, and to overcome the shortcomings of existing improvement schemes that only optimize the shearing link, have control lag, and are based on inaccurate data. Figures 1 to 3As shown, the gantry shear lifting control device implementing this method mainly includes a working platform 1, a pressing actuator 3 (specifically a pressing block device), a shearing actuator 2 (specifically a shearing moving blade device), a control system, and a pushing hopper 4. The components are connected by a precise mechanical layout and electrical connection to form a highly efficient and coordinated automated system.

[0084] The working platform 1 extends along the material conveying direction (i.e., the pushing direction) and consists of a pushing platform, a pressing platform, and a shearing platform that are on the same reference horizontal plane and seamlessly connected in sequence. These three platforms together form a continuous material carrying and processing plane, ensuring that the material can be smoothly conveyed from the feeding end to the discharging end.

[0085] The material pushing bin 4 is located at the beginning of the continuous working plane. Its discharge port is directly connected to the material pushing platform and its working surface is flush with the platform. It is used to store the material pile to be processed. The material pushing bin 4 is equipped with a material pushing block 41. The material pushing block 41 can reciprocate along the material pushing bin 4 under power drive. Its single pushing stroke is a fixed distance d. It is responsible for quantitatively pushing the material in the material pushing bin 4 to the material pushing platform.

[0086] The pressing actuator 3 is located above the pressing platform and mainly includes a pressing block 32, a first hydraulic cylinder 31 that drives the pressing block 32 to rise and fall, and a second distance sensor for monitoring the height of the pressing block 32.

[0087] The shearing actuator 2 is mounted above the shearing platform and mainly includes a movable blade holder 22 on which a movable blade 23 is installed, a second hydraulic cylinder 21 that drives the movable blade holder 22 to rise and fall, and a third distance sensor 24 for monitoring the height of the movable blade holder 22.

[0088] The crucial thickness detection function is achieved by the first distance sensor 5. The first distance sensor 5 is installed above the side of the pushing hopper 4 closest to the pressing platform. Its installation position along the pushing direction is set at a distance of twice the pushing stroke (2d) from the starting position of the pushing platform (i.e., the point of connection with the hopper outlet) in the direction inward from the hopper. That is, when the pushing block 41 pushes the material pile out of the hopper and advances it to a distance of twice the pushing stroke (2d) from the pressing platform, the first distance sensor 5 is just able to scan the material pile.

[0089] The control system (preferably a PLC control system) serves as the brain of the entire device. It is connected to the first ranging sensor 5, the second ranging sensor, the third ranging sensor 24, the first hydraulic cylinder 31, the second hydraulic cylinder 21, and the pushing mechanism that drives the pushing block 41 via electrical lines and signal lines. It is responsible for collecting all sensor signals, executing the core control algorithm, and outputting instructions to drive the actions of each actuator.

[0090] like Figure 4As shown, the gantry shear lifting control method of the present invention includes the following steps:

[0091] Step S1: Before the material is transferred to the pressing station and shearing station of the gantry shear, obtain the thickness parameters of the material to be processed in its original stacked state at the pushing station.

[0092] A series of distance measurements Δh1 between the first ranging sensor 5 (such as a laser ranging sensor) and the surface of the material pile are obtained; the minimum value Δh1_min is found from the series of distance measurements Δh1, which corresponds to the highest point of the material pile; the minimum value Δh1_min is subtracted from the preset fixed distance H1 (i.e., the installation height) between the measuring reference plane of the first ranging sensor 5 and the bearing surface of the working platform (i.e., the upper surface of the pushing platform), and the difference is the thickness parameter H. th , which is a parameter characterizing the maximum thickness of the material pile.

[0093] In a specific embodiment, a series of distance measurement values ​​can be obtained through the first ranging sensor 5 in any of the following ways:

[0094] Method 1 (Mobile): The single first ranging sensor 5 automatically reciprocates along a direction parallel to the width of the pusher hopper 4, and continuously measures during the movement.

[0095] Method 2 (array type): Set multiple or continuously linearly arranged ranging sensors as the first ranging sensor 5, and perform a one-time synchronous measurement.

[0096] Step S2: Based on the thickness parameters obtained in step S1, simultaneously determine the first target lifting height of the pressing actuator 3 and the second target lifting height of the shearing actuator 2.

[0097] The control system is based on the thickness parameter H obtained in step S1 th Simultaneously and independently calculate the lift height of the two targets:

[0098] The first target elevation height H ps : Set the lifting height for pressure block 32, calculated using the formula H ps =H th +α, where α is the preset minimum safety gap for pressing material.

[0099] Second target elevation height H cm The lifting height of the shearing moving blade holder 22 is set by the formula H. cm =H th +β, where β is the preset minimum safety clearance for shearing.

[0100] Step S3: Control the lifting of the pressing actuator 3 and monitor its height relative to the bearing surface of the working platform of the pressing station in real time during the lifting process. When the monitored height reaches the first target lifting height, control the pressing actuator 3 to stop lifting.

[0101] Step S3 aims to independently and in real-time monitor and precisely control the lifting process of the pressing actuator 3. During the lifting process of the pressing block 32, there are two preferred methods for real-time monitoring of the height of the pressing block 32 relative to the bearing surface of the working platform of the pressing station (i.e., the upper surface of the pressing platform):

[0102] The first type (direct distance measurement closed-loop control): During the lifting process of the pressure block 32, the second distance measurement sensor directly measures the first real-time distance between the lower surface of the pressure block 32 and the bearing surface of the pressure platform; the control system continuously compares the first real-time distance with the first target lifting height. When the first real-time distance is equal to the first target lifting height, it immediately outputs a command to stop the first hydraulic cylinder 31 and the pressure block 32 stops lifting.

[0103] The second method (indirect conversion closed-loop control): A second distance sensor located above the pressing station is aligned with a designated reference surface above the pressing block 32 (e.g., the upper surface of the pressing block 32); during the lifting process of the pressing block 32, the second distance sensor measures the first measurement distance value Δh2 in real time; the control system uses the formula: h2=(H2-h p H2 - Δh2, calculate the first real-time clearance distance h2, where H2 represents the preset installation height of the second ranging sensor, h p This indicates the known structural height of the pressure block 32. When the first real-time clearance distance equals the first target lifting height, a command is immediately output to stop the first hydraulic cylinder 31, and the pressure block 32 stops lifting.

[0104] Step S4: Control the shearing actuator 2 to lift, and monitor its height relative to the working platform bearing surface of the shearing station in real time during the lifting process. When the monitored height reaches the second target lifting height, control the shearing actuator 2 to stop lifting.

[0105] Step S4 aims to independently and in real-time monitor and precisely control the lifting process of the shearing actuator 2. During the lifting process of the moving cutter holder 22, there are two preferred methods for real-time monitoring of the height of the moving cutter holder 22 relative to the bearing surface of the working platform of the shearing station (i.e., the upper surface of the shearing platform):

[0106] The first type (direct distance measurement closed-loop control): During the lifting process of the moving cutter holder 22, the third distance sensor 24 directly measures the second real-time distance between the lower surface of the moving cutter holder 22 and the bearing surface of the shearing platform; the control system continuously compares the second real-time distance with the second target lifting height. When the second real-time distance is equal to the second target lifting height, it immediately outputs a command to stop the second hydraulic cylinder 21 and the moving cutter holder 22 stops lifting.

[0107] The second method (indirect conversion closed-loop control): The third distance sensor 24 located above the shearing station is aligned with a designated reference surface above the moving cutter holder 22; during the lifting process of the moving cutter holder 22, the third distance sensor 24 measures the second measurement distance value Δh3 in real time; the control system uses the formula: h3=(H3-h c )-Δh3, calculate the second real-time clearance distance h3, where H3 represents the preset installation height of the third ranging sensor 24, h c This indicates the known structural height of the moving tool holder 22. When the second real-time clearance distance equals the second target lifting height, a command is immediately output to stop the second hydraulic cylinder 21 and stop the moving tool holder 22 from lifting.

[0108] In a specific embodiment of the present invention, the method comprises two stages: initialization and continuous automatic operation. Before starting continuous production, the system performs initialization by executing any of the following processes:

[0109] Process 1: The system performs a pressing and shearing operation without pushing the material. Simultaneously, the first ranging sensor 5 scans the hopper, executing steps S1 and S2 to complete the initial thickness parameter H. th and the first target elevation height H ps The second target's elevation height H cm The determination is made. After the shearing operation is completed, the pressing actuator 3 and the shearing actuator 2 are raised and controlled at H according to steps S3 and S4. ps and H cm The system will then stop at a certain height. It will then transition to a continuous automatic operation process.

[0110] Step 2: The system first raises the pressing actuator 3 and the shearing actuator 2 to their highest positions. During this process or after they reach their positions, the first ranging sensor 5 scans the hopper to complete the initial thickness parameter H. th and the first target elevation height H ps The second target's elevation height H cm The determination is then made. Subsequently, a complete pushing, pressing, and shearing operation is performed. After the shearing is completed, the pressing actuator 3 and the shearing actuator 2 are raised and controlled at H according to steps S3 and S4. ps and H cm The system will then stop at a certain height. It will then transition to a continuous automatic operation process.

[0111] Once the continuous automatic operation process begins, the system will continue operating in the following loop:

[0112] Step A1: Perform one push, press, and shear operation.

[0113] Step A2: After the shearing operation is completed, immediately control the lifting of the pressing actuator 3 and the shearing actuator 2, and control them to stop at the first target lifting height H used in the current cycle according to steps S3 and S4. ps With the second target's elevation height H cm .

[0114] Step A3: The moment the pressing actuator 3 stops lifting, the first ranging sensor 5 is immediately triggered to rescan the hopper, executing steps S1 and S2 for the next cycle to obtain new thickness parameters and calculate the new first target lifting height and second target lifting height. After the calculation is completed, return to step A1 to start a new cycle.

[0115] Through the above implementation methods, this invention achieves the forward acquisition of the original thickness of the material during the feeding stage, and accordingly, dynamically sets the lifting height of the pressing and shearing actuators 2 simultaneously and independently, ensuring precise stopping through high-precision closed-loop control. This systematically eliminates the ineffective idle strokes of the two stages, significantly shortens the operation cycle, improves production efficiency, and overcomes the problems of single optimization and lagging control in existing technologies.

[0116] Example 2

[0117] This embodiment provides a gantry shear lifting control device based on material pusher thickness detection to implement the method of Embodiment 1. This device is the core control part of the gantry shear equipment. Through the coordinated work of hardware modules, it physically implements the control method in Embodiment 1.

[0118] like Figures 1 to 3 As shown, this device mainly includes a working platform 1, a thickness parameter detection module (first distance sensor 5), a first height detection module, a second height detection module, a controller (control system), a pressing actuator 3, and a shearing actuator 2.

[0119] The working platform 1 extends along the material conveying direction (i.e., the pushing direction) and consists of a pushing platform, a pressing platform, and a shearing platform that are on the same reference horizontal plane and seamlessly connected in sequence. These three platforms together form a continuous material carrying and processing plane, ensuring that the material can be smoothly conveyed from the feeding end to the discharging end.

[0120] The thickness parameter detection module is specifically the first distance sensor 5. The first distance sensor 5 is installed above the side of the pushing hopper 4 near the pressing platform. Its installation position along the pushing direction is set at a distance of twice the pushing stroke (2d) from the starting position of the pushing platform (i.e., the point of connection with the hopper outlet) in the direction inward from the hopper. That is, when the pushing block 41 pushes the material pile out of the hopper and advances it to a distance of twice the pushing stroke (2d) from the pressing platform, the first distance sensor 5 can just scan the material pile. The thickness parameter detection module is used to measure the thickness of the material pile in its original stacked state and output the thickness parameter (H). th ).

[0121] The first height detection module is located at the pressing station, specifically as the second distance sensor, installed above the pressing platform. The first height detection module is used to detect the height of the pressing actuator 3 relative to the working platform bearing surface (i.e., the surface of the pressing platform) of the pressing station in real time during the lifting process of the pressing actuator 3, and to generate a corresponding first height detection signal.

[0122] The second height detection module is located at the shearing station, specifically as the third distance sensor 24, installed above the shearing platform. This module detects the height of the shearing actuator 2 relative to the working platform bearing surface (i.e., the shearing platform surface) of the shearing station in real time during the lifting process of the shearing actuator 2, and generates a corresponding second height detection signal.

[0123] The controller is a control system, preferably a programmable logic controller (PLC). The controller is connected to the first ranging sensor 5, the second ranging sensor, and the third ranging sensor 24, respectively, to receive thickness parameters and the first and second height detection signals. Simultaneously, the controller is connected to the drive units (such as pusher cylinders) of the pressing actuator 3, the shearing actuator 2, and the pushing hopper 4.

[0124] The pressing mechanism 3, also known as the pressing block device, is positioned above the pressing platform. It mainly includes a pressing block 32 and a first hydraulic cylinder 31 that drives the pressing block 32 to rise and fall. The first hydraulic cylinder 31 is connected to the controller and is used to perform the pressing operation. It performs the lifting action in response to the control signal of the controller and stops lifting in response to the first stop lifting command issued by the controller.

[0125] The shearing actuator 2, also known as the shearing moving blade device, is mounted above the shearing platform. It mainly includes a moving blade holder 22 on which the moving blade 23 is installed, and a second hydraulic cylinder 21 that drives its lifting and lowering. The second hydraulic cylinder 21 is connected to the controller and is used to perform the shearing operation. It performs the lifting action in response to the controller's control signal and stops lifting in response to the second stop lifting command issued by the controller.

[0126] The gantry shear lifting control device provided in this embodiment achieves closed-loop lifting control through the coordination of the above modules. Its working logic is as follows:

[0127] Parameter detection and calculation: In the automatic operation cycle, the thickness parameter detection module (first ranging sensor 5) works first to acquire the thickness parameter H. th And send it to the controller; the controller bases it on the thickness parameter H. th Simultaneously determine the first target lifting height H of the material pressing actuator 3. ps The second target lifting height H of the shearing actuator 2 cm The determination method is based on the thickness parameter H. th Based on the baseline, and superimposed with the corresponding preset safety values ​​(α, β), i.e., H ps =H th +α,H cm =H th +β.

[0128] Operation execution and lifting monitoring: The controller controls the sequential execution of the pushing, pressing, and shearing operations. After the shearing operation is completed, the controller issues a command to control the pressing actuator 3 and the shearing actuator 2 to begin lifting.

[0129] Closed-loop lift control:

[0130] During the lifting process of the pressing actuator 3, the first height detection module (second distance sensor) detects its height in real time and feeds back the first height detection signal to the controller. The controller determines whether the real-time height of the pressing actuator 3 has reached the first target lifting height H based on the first height detection signal. ps When the judgment is "yes", the first stop lifting command is immediately issued to the pressing actuator 3 (first oil cylinder 31) to stop it precisely.

[0131] During the lifting process of the shearing actuator 2, the second height detection module (third distance sensor 24) detects its height in real time and feeds back the second height detection signal to the controller. The controller determines whether the real-time height of the shearing actuator 2 has reached the second target lifting height H based on the second height detection signal. cm When the judgment is "yes", a second stop lifting command is immediately issued to the shearing actuator 2 (second hydraulic cylinder 21) to bring it to a precise stop.

[0132] Cyclic and Adaptive Operation: In continuous automatic operation mode, when the material pressing actuator 3 stops lifting, the controller immediately triggers the thickness parameter detection module to perform the next measurement, updating the thickness parameter and the first target lifting height H. ps Second target lift height H cm This prepares the production cycle for the next work cycle, thereby enabling continuous optimization of the production takt time.

[0133] In some specific embodiments of the present invention, the gantry shear lifting control device can incorporate the features of the gantry shear lifting control method in Embodiment 1 of the present invention, and vice versa, which will not be elaborated here.

[0134] Through the aforementioned hardware configuration and control logic, this device physically achieves dynamic, synchronous, forward-looking optimization and precise closed-loop control of the lifting height of the gantry shear pressing and shearing stages, effectively improving equipment efficiency.

[0135] The above description only discloses specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or modifications that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A gantry shear lifting control method based on material pusher thickness detection, characterized in that, The control method includes: Before the material is transferred to the pressing station and the shearing station of the gantry shear, the thickness parameters of the material to be processed in its original stacked state are obtained at the pushing station. Based on the thickness parameter, the first target lifting height of the pressing actuator and the second target lifting height of the shearing actuator are determined simultaneously; wherein, the determination of the first target lifting height and the second target lifting height are based on the thickness parameter and superimposed with the corresponding preset safety value; The material pressing actuator is controlled to lift, and its height relative to the bearing surface of the work platform of the material pressing station is monitored in real time during the lifting process. When the monitored height reaches the first target lifting height, the material pressing actuator is controlled to stop lifting. The shearing actuator is controlled to lift, and its height relative to the working platform bearing surface of the shearing station is monitored in real time during the lifting process. When the monitored height reaches the second target lifting height, the shearing actuator is controlled to stop lifting.

2. The gantry shear lifting control method based on material pusher thickness detection according to claim 1, characterized in that, The process of obtaining the thickness parameters of the material pile in its original stacking state includes: A series of distance measurements between the material pile surface and the first ranging sensor are obtained. Find the minimum value from the series of distance measurements; The thickness parameter is obtained by subtracting the minimum value from the preset fixed distance between the measurement reference surface of the first ranging sensor and the bearing surface of the working platform.

3. The gantry shear lifting control method based on material pusher thickness detection according to claim 2, characterized in that, A series of distance measurements are acquired using a first ranging sensor, including any of the following methods: Method 1: Move a single first ranging sensor along a direction parallel to the width of the material pusher hopper, and continuously measure during the movement; Method 2: Set multiple or continuously linearly arranged ranging sensors as the first ranging sensor and perform synchronous measurements.

4. The gantry shear lifting control method based on material pusher thickness detection according to claim 1, characterized in that, The first target lifting height is the set lifting height of the pressure block, and its specific calculation formula is as follows: H ps =H th +a; Among them, H ps Indicates the set lifting height of the pressure block; H th This represents the thickness parameter; α represents the preset minimum safety clearance for the material. The second target lifting height is the set lifting height of the shearing moving blade holder, and its specific calculation formula is as follows: H cm =H th +β; Among them, H cm β indicates the set lifting height of the shearing moving blade holder; β indicates the preset minimum safety clearance for shearing.

5. The gantry shear lifting control method based on material pusher thickness detection according to claim 1, characterized in that, Real-time monitoring of the height of the material pressing actuator relative to the bearing surface of the working platform of the material pressing station includes: A second distance sensor installed above the pressing station directly and in real time measures the first real-time distance between the lower surface of the pressing actuator and the pressing platform; when the first real-time distance is equal to the first target lifting height, it is determined that the monitored height has reached the first target lifting height. Real-time monitoring of the height of the shearing actuator relative to the bearing surface of the working platform of the shearing station includes: A third distance sensor installed above the shearing station directly measures the second real-time distance between the lower surface of the shearing actuator and the shearing platform; when the second real-time distance is equal to the second target lifting height, it is determined that the monitored height has reached the second target lifting height.

6. The gantry shear lifting control method based on material pusher thickness detection according to claim 1, characterized in that, Real-time monitoring of the height of the material pressing actuator relative to the bearing surface of the working platform of the material pressing station includes: The first measurement distance value between the second distance sensor and the designated reference surface on the material pressing actuator is measured in real time using the second distance sensor. Based on the first measured distance value, the preset installation height of the second ranging sensor, and the known structural height of the pressing actuator, the first real-time clearance distance between the lower surface of the pressing actuator and the bearing surface of the working platform is calculated; wherein, the first real-time clearance distance = (preset installation height of the second ranging sensor - known structural height of the pressing actuator) - first measured distance value; Real-time monitoring of the height of the shearing actuator relative to the bearing surface of the working platform of the shearing station includes: The second measurement distance value between the third distance sensor and the designated reference surface on the shearing actuator is measured in real time using the third distance sensor. Based on the second measured distance value, the preset installation height of the third ranging sensor, and the known structural height of the shearing actuator, the second real-time clearance distance between the lower surface of the shearing actuator and the bearing surface of the working platform is calculated; wherein, the second real-time clearance distance = (preset installation height of the third ranging sensor - known structural height of the shearing actuator) - second measured distance value.

7. The gantry shear lifting control method based on material pusher thickness detection according to any one of claims 1 to 6, characterized in that, When the method starts an automated job, it executes any of the following processes: Process 1: Perform a pressing and shearing operation without pushing the material. During this process, the thickness parameter is acquired and the first target lifting height and the second target lifting height are determined accordingly. After the current shearing operation is completed, the pressing and shearing actuators are controlled to lift, and their heights are monitored in real time until they reach the corresponding target lifting heights determined based on the thickness parameter. Then, the process jumps to the continuous automatic operation process. Step 2: First, raise the pressing and shearing actuators to their highest positions. During this process or after they reach their positions, acquire the thickness parameters and determine the first and second target lifting heights accordingly. Then, execute a complete operation including pushing, pressing, and shearing. After the current shearing operation is completed, control the pressing and shearing actuators to lift, while monitoring their heights in real time, until they reach the corresponding target lifting heights determined based on the thickness parameters, and then stop. Then, switch to the continuous automatic operation process.

8. The gantry shear lifting control method based on material pusher thickness detection according to claim 7, characterized in that, The continuous automated operation process includes the following steps, which are executed periodically: Step A1: Perform the material pushing, pressing, and shearing operations; Step A2: After the shearing operation is completed, control the pressing mechanism and the shearing mechanism to lift, and monitor their height in real time until the monitored heights reach the first target lifting height and the second target lifting height determined in the current cycle, respectively, and then stop. Step A3: When the pressing actuator stops lifting, re-execute the steps of obtaining the thickness parameters of the material pile to be processed and determining the target lifting height, and then return to step A1.

9. A gantry shear lifting control device based on material pusher thickness detection, characterized in that, The control device includes: The thickness parameter detection module is located at the pushing station of the gantry shear and is used to measure and output the thickness parameter of the material pile to be processed before the material is transferred to the pressing station and the cutting station of the gantry shear. The first height detection module is located at the pressing station and is used to detect the height of the pressing actuator relative to the bearing surface of the working platform of the pressing station in real time during the lifting process of the pressing actuator, and generate the corresponding first height detection signal. The second height detection module is located at the shearing station and is used to detect the height of the shearing actuator relative to the working platform bearing surface of the shearing station in real time during the lifting process of the shearing actuator, and generate the corresponding second height detection signal. Controller, used for: Based on the received thickness parameters, the first target lifting height of the pressing actuator and the second target lifting height of the shearing actuator are simultaneously determined; wherein, the determination of the first target lifting height and the second target lifting height are based on the thickness parameters and superimposed with corresponding preset safety values; During the lifting process of the material pressing actuator, it is determined whether the real-time height of the material pressing actuator has reached the first target lifting height based on the received first height detection signal, and if the determination is yes, a first stop lifting command is issued to the material pressing actuator; During the lifting process of the shearing actuator, the real-time height of the shearing actuator is determined based on the received second height detection signal to determine whether the second target lifting height has been reached, and if the determination is yes, a second stop lifting command is issued to the shearing actuator; The material pressing actuator is connected to the controller for performing material pressing operations, and performs lifting actions in response to the control signal of the controller and stops lifting in response to the first stop lifting command; The shearing actuator is connected to the controller for performing shearing operations, and performs lifting actions in response to the control signal of the controller and stops lifting in response to the second stop lifting command.

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