A peak-shaving method for wire-based robot based on multiple wire accumulation machines

Abstract

The present application belongs to the technical field of metal wire heat treatment automation production, and particularly relates to a line control robot staggered peak operation method based on multiple wire accumulators, which is based on an operation system composed of a wire accumulator, a line control robot, a control system and a monitoring system, and realizes staggered peak operation by real-time monitoring of the number of winding turns and the steel wire surplus, evaluating the line control robot line changing capacity, constructing a priority judgment mechanism and triggering the "re-accumulation" function of the wire accumulator to realize staggered peak line changing and synchronously optimize the cyclic operation process. The present application realizes optimal allocation of wire accumulator resources, reduces equipment downtime, maintains stable steel wire tension and heat treatment time, increases comprehensive capacity by 15%-20%, reduces labor input by about 40%, has the advantages of intelligence, systematization, flexibility and digitization, and provides a replicable intelligent upgrading scheme for the metal wire heat treatment industry.

Description

Technical Field

[0001] This invention belongs to the field of automated production technology for heat treatment of metal wire, and specifically relates to a method for staggered operation of wire-controlled robots based on multiple wire accumulation machines. Background Technology

[0002] In the heat treatment process of metal wire, the wire winding machine is the core device. Its "re-winding" function enables non-stop material changing, evenly winding the steel wire onto the I-beams on the wire winding machine, ensuring continuous production. Currently, two heat treatment production lines are typically equipped with one wire-controlled robot and four wire winding machines, needing to process I-beams on 96 trays. This operation mode faces the following technical bottlenecks:

[0003] 1. Low line change efficiency: When two I-beams on a production line accumulate wire at the same time and need to be replaced, the wire-controlled robot cannot process them synchronously in a short time, causing one machine to stop for line change, which in turn leads to wire waste or wire breakage, affecting the smoothness of production. 2. Uneven resource allocation: When multiple production lines and multiple yarn-forming machines work together, the lack of a unified intelligent scheduling mechanism leads to low utilization rates of yarn-forming robots and wire-controlled robots. Equipment idleness and operation congestion coexist, which restricts on-site production efficiency. 3. Unstable heat treatment quality: When the wire accumulation robot cannot complete the replacement of 2-4 I-beams in a short time, the equipment must be forced to stop, resulting in fluctuations in wire tension and excessively long heat treatment time, which damages the consistency of product quality and reduces the output rate of qualified products. Therefore, there is an urgent need for an operational method that can optimize resource scheduling, improve line switching efficiency, and ensure heat treatment quality, thereby addressing the shortcomings of existing technologies. Summary of the Invention

[0004] To address the aforementioned problems in the existing technology, this invention provides a method for staggered operation of wire-controlled robots based on multiple wire-forming machines. This method is implemented using an operational system comprising wire-forming machines, wire-controlled robots, a control system, and a monitoring system. Four wire-forming machines are configured in pairs on two production lines to wind the steel wire from the spools that need to be replaced onto the machines. The wire-controlled robots are equipped with dedicated grippers, vision, and coordinate guidance modules for replacing the spools. The control system controls the wire-forming machines to select wire and perform wire-forming operations, and controls the wire-controlled robots to perform spool replacement operations. The monitoring system provides real-time feedback on the number of coils wound, time, and tray number from the wire-forming machines. The method includes the following steps: S1. Initial Operation: Two wire winding machines on the same production line start synchronously and perform winding operations according to preset parameters; S2. Real-time monitoring: Real-time feedback on the number of turns wound by the two wire accumulation machines, and real-time monitoring of wire diameter speed through encoder; S3. Remaining wire quantity detection: Manually confirm whether the remaining wire quantity of the two I-beams is equal. If the remaining quantities are not equal, proceed to the normal wire changing process; if the remaining quantities are equal, evaluate the wire-controlled robot's wire changing capability. S4. Robot Capability Assessment: Determine whether the wire-controlled robot can complete the two I-beam reel changes within 5 minutes to avoid wire diameter interruption during heat treatment. If it can, execute the normal wire change process; if it cannot, trigger the re-fiber stacking requirement and enter the priority judgment. S5. Priority Judgment: First, compare the wire allowance of the two I-beams. If the difference in allowance is significant, prioritize processing the side with less allowance. If the allowance is similar, compare the status of the wire accumulation machine. S6. Equipment Status Comparison: Based on equipment operating parameters, select the wire accumulator with better health status as the priority processing target; S7. Re-winding: Start the "re-winding" mode of the selected wire winding machine, and wind the remaining steel wire onto the transition turntable of the wire winding machine in advance. Simultaneously control the wire-controlled robot to complete the replacement of the I-beam, so as to ensure the continuity of the heat treatment process. S8. Cycle Optimization: After the line change is completed, the control system resets the operating parameters and returns to step S1 to enter the next work cycle.

[0005] Preferably, the wire accumulation machine is a heat treatment wire-controlled wire accumulation machine installed in front of the heat treatment boiler, and the wire accumulation machine is equipped with a constant tension control system to ensure that the wire accumulation does not conflict with the speed of the take-up machine and that the wire release matches the speed of the take-up machine.

[0006] Preferably, the two wire accumulation machines in each production line operate in parallel.

[0007] Preferably, the wire-controlled robot is model CX030806JL01, which can automatically change between 900 and 1250 type I-beam reels, receive commands from the control system to execute actions, and ensure that the wire specifications are consistent after replacement.

[0008] Preferably, the control system adopts an industrial PLC controller, whose function is to coordinate the wire stacking machine to perform constant tension control so that the steel wire is heat-treated according to the process requirements.

[0009] Preferably, the monitoring system includes a human-machine interface and integrates upper-level smart factory software, which can support real-time data visualization, fault alarms, and manual intervention.

[0010] The beneficial effects of this invention are: (1) Solve core technical problems: Through the algorithm of margin detection, robot capability assessment and priority judgment, realize the dynamic optimal allocation of wire accumulation machine resources and avoid the overall efficiency decline caused by single station shutdown; through automated line changing and wire accumulation operation, reduce manual intervention, maintain the stability of wire tension and heat treatment time, and improve product quality consistency. (2) Significantly improve production efficiency: The staggered line change strategy effectively reduces equipment downtime. Practical experience has shown that the overall production capacity can be increased by 15%-20%. The work process is executed in a standardized manner through the system's preset program, eliminating the randomness of human operation and ensuring that each step meets the process standards.

[0011] (3) Reduce costs and losses: The constant tension control system adjusts the wire tension in real time to avoid wire deformation or equipment damage caused by abnormal wire pulling speed; the wire changing process only requires manual confirmation of key nodes, replacing the original multi-person collaborative operation, reducing manual input by about 40%. (4) It has the advantages of flexibility and digitalization: it can adapt to the requirements of different specifications of steel wire and heat treatment process, support rapid line change and process adjustment; the whole process data collection and accumulation provides data support for process parameter optimization and refined management, breaks the information silos of equipment, and realizes multi-equipment collaborative control and intelligent decision-making. Attached Figure Description

[0012] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0013] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0014] The present invention will now be clearly described with reference to the accompanying drawings and specific embodiments. This description is merely illustrative and is not intended to limit the scope of the invention. Any modifications, equivalent substitutions, or improvements made by those skilled in the art based on the embodiments of the present invention without inventive effort to obtain all other embodiments should be included within the scope of protection of the present invention.

[0015] Example This embodiment is applied to two metal wire heat treatment production lines, and the operating system configuration is as follows: 1. Wire stacking robot: 2 wire-controlled wire stacking machines for heat treatment are installed in front of the heat treatment boiler, with 2 machines arranged in parallel on each production line; the constant tension control range is 5-15N, the winding accuracy is ±0.5 turns, the real-time feedback data update frequency of the flat plate is 1 time / second, and it receives the wire stacking task instructions issued by the upper computer smart factory software. 2. Wire-controlled robot: Model CX030806JL01, with fixtures compatible with 900mm and 1250mm I-beam wheels, visual positioning accuracy ±1mm, single line change time ≤3 minutes, receives line change commands from PLC control system and provides feedback on execution status. 3. PLC control system: Siemens S7-1500 series industrial PLC is adopted to control the wire selection response time of the wire accumulation machine's gripper to ≤0.2 seconds, and the constant tension dynamic adjustment frequency to 5 times / second, ensuring that the wire accumulation speed matches the winding machine speed (10-20m / min). 4. Monitoring System: The human-machine interface (HMI) adopts a touch screen, which supports fault alarm pop-ups and manual intervention command input; the upper computer smart factory software adopts WinCC, which collects data such as winding coil number, tension value, and changeover time in real time, generates work reports, and supports data export and traceability. Combination Figure 1 As shown, the specific implementation steps are as follows: S1. Initial Operation: Start two production lines. Two wire accumulation machines synchronously perform winding operations according to preset parameters (winding speed 15m / min, tension 8N). The PLC control system coordinates the speed matching between the wire accumulation mechanism and the take-up machine. The monitoring system starts the data acquisition and visualization functions. S2. Real-time monitoring: The encoder monitors the wire diameter speed in real time. The wire accumulation machine plate updates the winding coil number, operation time, and tray number data every 1 second. If the wire diameter speed fluctuates more than ±1m / min, the monitoring system will issue an early warning. S3. Remaining wire quantity detection: When the number of turns reaches the preset threshold (e.g., 1000 turns), the remaining wire quantity of the two I-beams is confirmed by combining the data from the tablet with on-site observation. If the remaining quantity at station A is 200 turns and at station B is 80 turns, the difference is significant. The wire-controlled robot is directly controlled to replace the I-beam at station B first. If the remaining quantity at both stations is around 150 turns, the robot capability assessment stage is entered. S4. Robot capability assessment: Determine whether the wire-controlled robot can complete the dual-station line change within 5 minutes. Since the time for a single line change is ≤3 minutes, the continuous dual-station line change requires 6 minutes. If the 5-minute threshold is exceeded, the re-accumulation of wire is triggered. S5. Priority Judgment and Equipment Status Comparison: The remaining capacity of the two stations is similar. Further comparison of the status of the wire accumulation machine shows that the wire accumulation machine at station A has accumulated 8 hours of operation with no fault records; the wire accumulation machine at station B has accumulated 12 hours of operation and has experienced one tension fluctuation warning. Therefore, the wire accumulation machine at station A is selected first to perform the re-accumulation operation. S6. Re-laying wire execution: Start the "re-laying wire" mode of the wire laying machine at station A, and wind 150 turns of the remaining steel wire onto the transition turntable (winding speed 12m / min). At the same time, control the wire-controlled robot to change the I-beam at station B (takes 2.8 minutes). After the wire change at station B is completed, the robot moves to station A to change the I-beam. At this time, the re-laying wire at station A is completed. The change takes 2.9 minutes. The entire heat treatment process is uninterrupted. S7. Cycle Optimization: After the line change is completed, the system automatically resets parameters such as the number of winding coils and tension value, returns to the initial operating state, and enters the next work cycle; the monitoring system records data such as the length of this line change and the range of tension fluctuations, and incorporates them into the process optimization database. After one month of operation, statistical data showed that the production line downtime was reduced by 60% compared to the original model, the overall production capacity increased by 18%, the wire waste rate decreased from 5% to 1.2%, the product quality consistency pass rate increased from 92% to 98.5%, and the manual input in the line changeover process decreased from 3 people / shift to 2 people / shift, which met the expected technical results.

[0016] The embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. A method for staggered operation of a wire-controlled robot based on multiple wire-forming machines, characterized in that: Based on an operational system including wire stacking machines, wire-controlled robots, control systems, and monitoring systems, the number of wire stacking machines is four, arranged in pairs on two production lines, used to wind the steel wire on the I-beams that need to be replaced onto the wire stacking machines; the wire-controlled robots are equipped with special clamps, vision and coordinate guidance modules, used to replace the I-beams; The control system is used to control the wire stacking machine to select wires and perform wire stacking operations, and to control the wire-controlled robot to perform the I-beam reel replacement operation; the monitoring system can provide real-time feedback on the number of coils wound, time, and tray number of the wire stacking machine. The method includes the following steps: S1. Initial Operation: Two wire winding machines on the same production line start synchronously and perform winding operations according to preset parameters; S2. Real-time monitoring: Real-time feedback on the number of turns wound by the two wire accumulation machines, and real-time monitoring of wire diameter speed through encoder; S3. Remaining wire quantity detection: Manually confirm whether the remaining wire quantity of the two I-beams is equal. If the remaining quantities are not equal, proceed to the normal wire changing process; if the remaining quantities are equal, evaluate the wire-controlled robot's wire changing capability. S4. Robot capability assessment: Determine whether the wire-controlled robot can complete the two I-beam line changes within 5 minutes. If it can, then execute the normal line change process. If not, then the need for re-accumulation of filaments is triggered, and priority judgment is entered; S5. Priority Judgment: First, compare the wire allowance of the two I-beams. If the difference in allowance is significant, prioritize processing the side with less allowance. If the allowance is similar, compare the status of the wire accumulation machine. S6. Equipment Status Comparison: Based on equipment operating parameters, select the wire accumulator with better health status as the priority processing target; S7. Re-winding: Start the "re-winding" mode of the selected wire winding machine, and wind the remaining steel wire onto the transition turntable of the wire winding machine in advance. Simultaneously control the wire-controlled robot to complete the replacement of the I-beam, so as to ensure the continuity of the heat treatment process. S8. Cycle Optimization: After the line change is completed, the control system resets the operating parameters and returns to step S1 to enter the next work cycle.

2. The method for staggered operation of a wire-controlled robot based on multiple wire-accumulating machines according to claim 1, characterized in that: The wire accumulation machine is a heat treatment line-controlled wire accumulation machine, installed in front of the heat treatment boiler, and equipped with a constant tension control system.

3. The method for staggered operation of a wire-controlled robot based on multiple wire-accumulating machines according to claim 2, characterized in that: Two wire forming machines operate in parallel on each production line.

4. The method for staggered operation of a wire-controlled robot based on multiple wire-accumulating machines according to claim 1, characterized in that: The model number of the wire-controlled robot is CX030806JL01.

5. The method for staggered operation of a wire-controlled robot based on multiple wire-forming machines according to claim 1, characterized in that: The control system uses an industrial PLC controller.

6. The method for staggered operation of a wire-controlled robot based on multiple wire-accumulating machines according to claim 1, characterized in that: The monitoring system includes a human-machine interface and integrates host computer smart factory software.

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