Automatic control system for wirelessly controlling movement mode of cold saw

Abstract

The invention provides an automatic control system for wirelessly controlling the movement mode of a cold saw. The automatic control system comprises an industrial remote controller, a wireless receiving module, a PLC, an upper computer monitoring system and at least N cold saw devices. The upper computer monitoring system sets enabling control buttons of the N cold saw devices through WinCC configuration pictures, interlocking control is achieved through a script program, and it is ensured that only one cold saw device obtains the control authority at any moment. The industrial remote controller generates wireless control signals, and instructions comprise rail clamping device switching, saw advancing / retreating, left-right moving and the like; and the wireless receiving module receives and decodes the signal and transmits the signal to the PLC. And the PLC performs instruction logic judgment and conversion according to the state of the cold sawing equipment, and outputs a control signal to drive the cold sawing equipment to act. The system has the beneficial effects that through wireless remote control and PLC intelligent control, the operation safety, the control reliability and the operation efficiency are improved, the manual operation risk is reduced, and the production process is optimized.

Description

Technical Field

[0001] This invention belongs to the field of automation control, and in particular relates to an automated control system for wirelessly controlling the movement of a cold saw. Background Technology

[0002] The reason why traditional cold saw control systems have been used for a long time is because they are "simple, stable, cheap and easy to use". They are practically reasonable in scenarios with low automation requirements and single-machine operation. However, with the increase in safety requirements, production efficiency and the need for multi-device collaboration, their limitations have gradually become apparent.

[0003] Traditional cold saw control systems have the following drawbacks: Traditional cold saw control systems typically lack a clear interlocking mechanism. Multiple cold saws may be activated simultaneously or misoperated, leading to conflicts or synchronization problems between devices and creating safety hazards. This affects operator and equipment safety, increasing the risk of potential equipment damage and personal injury.

[0004] Traditional cold saw control systems typically rely on manual operation for command control, lacking real-time status feedback and intelligent automatic adjustment mechanisms. When multiple machines are running, the accuracy of manual monitoring and adjustment is low, easily leading to uneven sawing, equipment malfunctions, and other problems. Furthermore, operators' real-time understanding of the equipment status is insufficient, potentially causing malfunctions to be overlooked, impacting production efficiency and equipment lifespan.

[0005] The control of different cold sawing machines may not be sufficiently automated and coordinated, and there may be a lack of precise synchronous control between the machines. For example, when multiple cold sawing machines are performing synchronous sawing, the lack of position closed-loop control can lead to inconsistent movements, affecting sawing quality and potentially causing equipment damage or low production efficiency. Summary of the Invention

[0006] In view of this, the present invention aims to provide an automated control system for wirelessly controlling the movement of a cold saw, in order to solve at least one of the aforementioned technical problems.

[0007] To achieve the above objectives, the technical solution of the present invention is implemented as follows: An automated control system for wirelessly controlling the movement of a cold saw, the system comprising an industrial remote controller, a wireless receiving module, a PLC controller, a host computer monitoring system, and at least N cold saw devices; The host computer monitoring system is based on the WinCC configuration screen and has enable control buttons corresponding to N cold saw devices. It also uses a script program to implement interlock control of multiple cold saw devices to ensure that only one cold saw device is allowed to obtain wireless control permission at any given time. The industrial remote controller is used to generate wireless control signals containing cold saw movement commands, which include at least the rail clamp opening command, the rail clamp closing command, the cold saw forward command, the cold saw backward command, the cold saw leftward command, and the cold saw rightward command. The wireless receiving module is used to receive and decode the wireless control signals sent by the industrial remote controller, and transmit the decoded action commands to the PLC controller; The PLC controller has a built-in instruction conversion program, which, upon receiving the action instruction, performs logical judgment and conversion on the action instruction in conjunction with the current working state of the cold saw equipment, and outputs the corresponding execution control signal to drive the cold saw equipment to operate.

[0008] Furthermore, when the rail clamp is in the closed state and the traverse motor brake is in the closed state, the PLC controller allows the cold saw to move forward or backward. When the rail clamp is in the open state and the lateral motor brake is in the open state, the PLC controller allows the cold saw to move to the left or right. The host computer monitoring system is equipped with a synchronous sawing mode control command. When the synchronous sawing mode is activated, the PLC controller performs closed-loop control on the relative positions of multiple cold sawing devices to achieve synchronous forward and backward movement of multiple cold sawing devices.

[0009] Furthermore, the wireless receiving module includes multiple wireless receiving units, each corresponding to a cold saw device, and performs real-time data synchronization between each cold saw device and other devices through a multi-band wireless communication protocol. The multi-band wireless communication protocol supports self-organizing network technology. When a device malfunctions, the system will automatically reallocate the signal communication path to ensure the stability and efficient transmission of the wireless signal.

[0010] Furthermore, the PLC controller has a built-in status monitoring module; The status monitoring module monitors the working status of the cold saw equipment and collects various operating parameters of the cold saw equipment through integrated sensors, including at least the on / off status of the rail clamp, the working status of the transverse motor, the sawing speed, the wear condition of the saw blade, and the vibration frequency of the equipment.

[0011] Furthermore, the host computer monitoring system has a built-in intelligent scheduling module based on artificial intelligence; The intelligent scheduling module integrates production planning management, load analysis, and equipment performance data, and combines them with the actual situation on the production site. It uses deep learning algorithms to optimize production scheduling and control strategies in real time, and adjusts the working mode and operation sequence of cold saw equipment under different production needs.

[0012] Furthermore, the wireless control signal is transmitted in encrypted form using a multi-layered encryption algorithm, including at least AES encryption and SSL / TLS transmission protocol; The receiving module integrates a signal authentication mechanism, which uses multi-factor authentication of device ID, password, and dynamic token to only receive commands from legally authorized remote controls; The system monitors illegal interference and signal tampering through a real-time monitoring module, and automatically triggers alarms and initiates emergency responses when security threats are detected.

[0013] Furthermore, the synchronous sawing mode control command has a built-in environmental adaptability function module; The environmental adaptability module integrates environmental sensors to collect environmental data in real time and dynamically adjusts the sawing speed, sawing pressure, and synchronization strategy based on the collected environmental data.

[0014] Furthermore, the PLC controller has a built-in fault self-diagnosis module; The fault self-diagnosis module integrates self-diagnosis algorithms and sensor data to detect the working status of the cold saw equipment in real time, determine whether there is a risk of failure, automatically generate a detailed fault report, and automatically switch to a safe mode according to the fault type of the equipment to lock the faulty component.

[0015] Furthermore, the system also includes: The remote maintenance module enables remote operation, real-time monitoring, and diagnostics via a cloud platform connected to the internet. The remote maintenance module allows real-time access to the status data, diagnostic information, and operation reports of the cold saw equipment. The cloud platform integrates a big data analytics module, which is used to perform in-depth analysis of the equipment's historical operating data, provide long-term maintenance predictions, and send early warning notifications to operators when the equipment is about to fail.

[0016] Furthermore, the system also includes: The data acquisition module is used to collect operating data of the cold saw equipment, including at least temperature, vibration, power consumption, and sawing progress. The operational data is uploaded to the cloud platform, which uses data mining and machine learning algorithms to analyze historical data and provide personalized maintenance plans for the cold saw equipment.

[0017] Compared with existing technologies, the automated control system for wirelessly controlling the movement of a cold saw described in this invention has the following advantages: By using the host computer's enable button and script interlocking mechanism, it is ensured that only one cold saw is allowed to obtain wireless control at any given time, effectively avoiding safety risks caused by multiple cold saws malfunctioning or moving simultaneously, and improving the inherent safety level of on-site operations.

[0018] The PLC performs status judgment and logic conversion on the wireless commands, ensuring that the cold saw action must meet the prerequisites such as the rail clamp, preventing misoperation or violation of regulations, ensuring the stability and controllability of the cold saw movement process, and improving the reliability of equipment operation.

[0019] By combining wireless remote control with centralized monitoring, the movement of the cold saw can be remotely and quickly controlled, reducing manual intervention and on-site operation intensity, and improving equipment response speed and overall production efficiency. Attached Figure Description

[0020] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the architecture of an automated control system for wirelessly controlling the movement of a cold saw, as described in an embodiment of the present invention. Detailed Implementation

[0021] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0022] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0025] An automated control system for wirelessly controlling the movement of a cold saw, the system comprising an industrial remote controller, a wireless receiving module, a PLC controller, a host computer monitoring system, and at least N cold saw devices; The host computer monitoring system is based on the WinCC configuration screen and has enable control buttons corresponding to N cold saw devices. It also uses a script program to implement interlock control of multiple cold saw devices to ensure that only one cold saw device is allowed to obtain wireless control permission at any given time. The industrial remote controller is used to generate wireless control signals containing cold saw movement commands, which include at least the rail clamp opening command, the rail clamp closing command, the cold saw forward command, the cold saw backward command, the cold saw leftward command, and the cold saw rightward command. The wireless receiving module is used to receive and decode the wireless control signals sent by the industrial remote controller, and transmit the decoded action commands to the PLC controller; The PLC controller has a built-in instruction conversion program, which, upon receiving the action instruction, performs logical judgment and conversion on the action instruction in conjunction with the current working state of the cold saw equipment, and outputs the corresponding execution control signal to drive the cold saw equipment to operate.

[0026] When the rail clamp is in the closed state and the traverse motor brake is in the closed state, the PLC controller allows the cold saw to move forward or backward. When the rail clamp is in the open state and the lateral motor brake is in the open state, the PLC controller allows the cold saw to move to the left or right. The host computer monitoring system is equipped with a synchronous sawing mode control command. When the synchronous sawing mode is activated, the PLC controller performs closed-loop control on the relative positions of multiple cold sawing devices to achieve synchronous forward and backward movement of multiple cold sawing devices.

[0027] The wireless receiving module includes multiple wireless receiving units, each corresponding to a cold saw device, and performs real-time data synchronization between each cold saw device and other devices through a multi-band wireless communication protocol. The multi-band wireless communication protocol supports self-organizing network technology. When a device malfunctions, the system will automatically reallocate the signal communication path to ensure the stability and efficient transmission of the wireless signal.

[0028] The PLC controller has a built-in status monitoring module; The status monitoring module monitors the working status of the cold saw equipment and collects various operating parameters of the cold saw equipment through integrated sensors, including at least the on / off status of the rail clamp, the working status of the transverse motor, the sawing speed, the wear condition of the saw blade, and the vibration frequency of the equipment.

[0029] The host computer monitoring system has a built-in intelligent scheduling module based on artificial intelligence; The intelligent scheduling module integrates production planning management, load analysis, and equipment performance data, and combines them with the actual situation on the production site. It uses deep learning algorithms to optimize production scheduling and control strategies in real time, and adjusts the working mode and operation sequence of cold saw equipment under different production needs.

[0030] The wireless control signal is transmitted in encrypted form using a multi-layered encryption algorithm, including at least AES encryption and SSL / TLS transmission protocol. The receiving module integrates a signal authentication mechanism, which uses multi-factor authentication of device ID, password, and dynamic token to only receive commands from legally authorized remote controls; The system monitors illegal interference and signal tampering through a real-time monitoring module, and automatically triggers alarms and initiates emergency responses when security threats are detected.

[0031] The synchronous sawing mode control command has a built-in environmental adaptability function module. The environmental adaptability module integrates environmental sensors to collect environmental data in real time and dynamically adjusts the sawing speed, sawing pressure, and synchronization strategy based on the collected environmental data.

[0032] The PLC controller has a built-in fault self-diagnosis module. The fault self-diagnosis module integrates self-diagnosis algorithms and sensor data to detect the working status of the cold saw equipment in real time, determine whether there is a risk of failure, automatically generate a detailed fault report, and automatically switch to a safe mode according to the fault type of the equipment to lock the faulty component.

[0033] The system also includes: The remote maintenance module enables remote operation, real-time monitoring, and diagnostics via a cloud platform connected to the internet. The remote maintenance module allows real-time access to the status data, diagnostic information, and operation reports of the cold saw equipment. The cloud platform integrates a big data analytics module, which is used to perform in-depth analysis of the equipment's historical operating data, provide long-term maintenance predictions, and send early warning notifications to operators when the equipment is about to fail.

[0034] The system also includes: The data acquisition module is used to collect operating data of the cold saw equipment, including at least temperature, vibration, power consumption, and sawing progress. The operational data is uploaded to the cloud platform, which uses data mining and machine learning algorithms to analyze historical data and provide personalized maintenance plans for the cold saw equipment.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

[0036] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automated control system for wirelessly controlling the movement of a cold saw, characterized in that, The system includes an industrial remote controller, a wireless receiving module, a PLC controller, a host computer monitoring system, and at least N cold sawing devices; The host computer monitoring system is based on the WinCC configuration screen and has enable control buttons corresponding to N cold saw devices. It also uses a script program to implement interlock control of multiple cold saw devices to ensure that only one cold saw device is allowed to obtain wireless control permission at any given time. The industrial remote controller is used to generate wireless control signals containing cold saw movement commands, which include at least the rail clamp opening command, the rail clamp closing command, the cold saw forward command, the cold saw backward command, the cold saw leftward command, and the cold saw rightward command. The wireless receiving module is used to receive and decode the wireless control signals sent by the industrial remote controller, and transmit the decoded action commands to the PLC controller; The PLC controller has a built-in instruction conversion program, which, upon receiving the action instruction, combines the current working state of the cold saw equipment to perform logical judgment and conversion on the action instruction, and outputs the corresponding execution control signal to drive the cold saw equipment to operate.

2. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that: When the rail clamp is in the closed state and the traverse motor brake is in the closed state, the PLC controller allows the cold saw to move forward or backward. When the rail clamp is in the open state and the lateral motor brake is in the open state, the PLC controller allows the cold saw to move to the left or right. The host computer monitoring system is equipped with a synchronous sawing mode control command. When the synchronous sawing mode is activated, the PLC controller performs closed-loop control on the relative positions of multiple cold sawing devices to achieve synchronous forward and backward movement of multiple cold sawing devices.

3. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that: The wireless receiving module includes multiple wireless receiving units, each corresponding to a cold saw device, and performs real-time data synchronization between each cold saw device and other devices through a multi-band wireless communication protocol. The multi-band wireless communication protocol supports self-organizing network technology. When a device malfunctions, the system automatically reallocates the signal communication path to ensure the stability and efficient transmission of the wireless signal.

4. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that: The PLC controller has a built-in status monitoring module; The status monitoring module monitors the working status of the cold saw equipment and collects various operating parameters of the cold saw equipment through integrated sensors, including at least the on / off status of the rail clamp, the working status of the transverse motor, the sawing speed, the wear condition of the saw blade, and the vibration frequency of the equipment.

5. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that: The host computer monitoring system has a built-in intelligent scheduling module based on artificial intelligence; The intelligent scheduling module integrates production planning management, load analysis, and equipment performance data, and combines them with the actual situation on the production site. It uses deep learning algorithms to optimize production scheduling and control strategies in real time, and adjusts the working mode and operation sequence of cold saw equipment under different production needs.

6. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that: The wireless control signal is transmitted in encrypted form using a multi-layered encryption algorithm, including at least AES encryption and SSL / TLS transmission protocol. The receiving module integrates a signal authentication mechanism, which uses multi-factor authentication of device ID, password, and dynamic token to only receive commands from legally authorized remote controls; The system monitors illegal interference and signal tampering through a real-time monitoring module, and automatically triggers alarms and initiates emergency responses when security threats are detected.

7. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that: The synchronous sawing mode control command has a built-in environmental adaptability function module. The environmental adaptability module integrates environmental sensors to collect environmental data in real time and dynamically adjusts the sawing speed, sawing pressure, and synchronization strategy based on the collected environmental data.

8. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that: The PLC controller has a built-in fault self-diagnosis module. The fault self-diagnosis module integrates self-diagnosis algorithms and sensor data to detect the working status of the cold saw equipment in real time, determine whether there is a risk of failure, automatically generate a detailed fault report, and automatically switch to a safe mode according to the fault type of the equipment to lock the faulty component.

9. The automated control system for wirelessly controlling the movement of a cold saw according to claim 1, characterized in that, The system also includes: The remote maintenance module enables remote operation, real-time monitoring, and diagnostics via a cloud platform connected to the internet. The remote maintenance module allows real-time access to the status data, diagnostic information, and operation reports of the cold saw equipment. The cloud platform integrates a big data analytics module, which is used to perform in-depth analysis of the equipment's historical operating data, provide long-term maintenance predictions, and send early warning notifications to operators when the equipment is about to fail.

10. An automated control system for wirelessly controlling the movement of a cold saw according to claim 9, characterized in that, The system also includes: The data acquisition module is used to collect operating data of the cold saw equipment, including at least temperature, vibration, power consumption, and sawing progress. The operational data is uploaded to the cloud platform, which uses data mining and machine learning algorithms to analyze historical data and provide personalized maintenance plans for the cold saw equipment.

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