A sampling shear crankshaft phase calibration system and method

Abstract

This application provides a sampling shear crankshaft phase calibration system and method, relating to the field of steel technology. The system includes a programmable logic controller (PLC) and a human-machine interface (HMI) module connected to each other. The HMI module is loaded with a crankshaft calibration interface, and the PLC is also connected to an encoder mounted on the crankshaft of the sampling shear. When the sampling shear stops within a preset phase zeroing range, the HMI module responds to a user-triggered operation on the crankshaft calibration interface and sends a calibration start signal to the PLC. Upon receiving the calibration start signal, the PLC executes an automatic calibration program based on the current encoder rotation angle value, calculates and updates the crankshaft calibration value, and corrects the crankshaft logical phase recorded in the system based on the updated crankshaft calibration value, so that the crankshaft logical phase is synchronously aligned with the actual mechanical phase of the crankshaft. This system achieves automated calibration of the sampling shear crankshaft phase, reducing operational difficulty and cost.

Description

Technical Field

[0001] This application relates to the field of steel technology, and more specifically, to a sampling shear crankshaft phase calibration system and method. Background Technology

[0002] As the core shearing equipment in the medium and heavy plate heat treatment production line of the medium and heavy plate plant, the sampling shear's operational stability directly affects the efficiency and quality of steel plate sampling. However, due to the complex equipment distribution and flawed equipment layout in the site environment, the originally configured centering device was frequently interfered with and damaged by the flipping machine's movements during actual operation, with an average of no fewer than two suction cups damaged per month, resulting in significant cost consumption. Simultaneously, this problem led to an equipment operating rate of less than 50%, severely impacting production collection efficiency and cost control. To maintain production, the factory removed the centering device and utilized the side flipping arm of the flipping machine's roller conveyor to replace it and complete the steel plate straightening function.

[0003] This modification meant that steel plates could only be fed into the shearing area from the north side of the roller conveyor, leading to a series of process problems during shearing: failures such as incomplete shearing, burr formation, and even blade jamming frequently occurred on the north side of the steel plate. To solve these problems, the production line underwent technical research and development to improve the shearing process, changing the direction of the shear blade from "south to north" to "north to south." The original sampling shearing process involved the steel plate being moved to the south side of the roller conveyor via a centering device, then fed to the sampling shear via the input roller conveyor, with the shear blade cutting downwards from south to north to complete the steel plate sampling and shearing. After the modification, to accommodate plates entering from the north, the shear blade needed to be changed to cut downwards from north to south. This adjustment was achieved by changing the motor excitation phase sequence, thereby changing the crankshaft rotation direction from clockwise to counterclockwise.

[0004] However, after the crankshaft rotation direction changes, a new problem arises regarding the crankshaft's stopping stability at its highest position (phase angle of 0° or 360°): approximately 1-2 times per shift, the crankshaft fails to stop stably at its highest position, leading to abnormalities such as cutter slippage, continuous shearing, or even damage to the steel plate. Manual intervention is required in these situations, adjusting the interface display value to match the actual mechanical position by manually rotating the coupling of the phase encoder shaft. This operation is not only time-consuming and labor-intensive but also frequently causes coupling damage, slippage, and jamming, posing safety hazards and increasing maintenance costs and downtime.

[0005] In summary, how to achieve automated calibration of the sampling shear crankshaft phase after canceling the centering device and changing the shearing direction, avoid unstable stopping, slippage and continuous shearing, and reduce maintenance difficulty and cost, is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] The purpose of this application is to provide a sampling shear crankshaft phase calibration system and method, so as to achieve automated calibration of the sampling shear crankshaft phase after canceling the centering device and changing the shearing direction, avoiding unstable parking, slippage and continuous shearing, and reducing maintenance difficulty and cost.

[0007] To achieve the above objectives, the technical solution adopted in this application is as follows: On one hand, this application provides a sampling shear crankshaft phase calibration system, including a programmable logic controller and a human-machine interaction module connected to each other; the human-machine interaction module is loaded with a crankshaft calibration interface, and the programmable logic controller is also connected to an encoder, which is installed on the crankshaft of the sampling shear; When the sampling shear stops within the preset phase zeroing range, the human-machine interaction module is used to respond to the user-triggered operation on the crankshaft calibration interface and send a calibration start signal to the programmable logic controller. When the calibration start signal is received, the programmable logic controller is used to execute an automatic calibration program based on the current encoder rotation angle value, calculate and update the crankshaft calibration value used to compensate for phase accumulation error, and correct the crankshaft logical phase recorded in the system based on the updated crankshaft calibration value, so that the crankshaft logical phase is synchronously aligned with the actual mechanical phase of the crankshaft.

[0008] Furthermore, the automatic calibration program in the programmable logic controller includes a first subtraction function block, a second subtraction function block, and an addition function block; The first subtraction function block is used to subtract a preset angle value from the current encoder rotation angle value when the rising edge of the calibration start signal is received, so as to obtain the updated crankshaft calibration value. The second subtraction function block is used to subtract the current encoder rotation angle value from 360° to obtain the angle deviation value; The addition function block is used to add the angle deviation value to the updated crankshaft calibration value to obtain the corrected crankshaft logic phase.

[0009] Furthermore, the automatic calibration program also includes a multiplication function block and a first transfer function block; The multiplication function block is used to multiply the cumulative number of pulses sent by the encoder by the encoder angle conversion coefficient to obtain the encoder rotation angle value; The first transmission function block is used to transmit the encoder rotation angle value to the first subtraction function block.

[0010] Furthermore, the automatic calibration program also includes a first comparison function block, a second comparison function block, a second transmission function block, and a third subtraction function block; The first comparison function block is used to send an enable signal to the second transmission function block when the corrected crankshaft logic phase is less than or equal to 360°; the second transmission function block is used to take the corrected crankshaft logic as the final crankshaft logic phase when it receives the enable signal. The second comparison function block is used to send an enable signal to the third subtraction function block when the corrected crankshaft logic phase is greater than 360°; the third subtraction function block is used to subtract 360° from the corrected crankshaft logic phase when the enable signal is received to obtain the final crankshaft logic phase.

[0011] Furthermore, the crankshaft calibration interface includes: a calibration button, an encoder angle display area, and a crankshaft calibration value display area; The calibration button is used to respond to a calibration command triggered by the user and send the calibration start signal to the programmable logic controller; The encoder angle display area is used to display the encoder rotation angle value in real time; The crankshaft calibration value display area is used to display the crankshaft calibration value in real time.

[0012] Furthermore, the human-computer interaction module also loads an interlocking interface; When the sampling shear is not stopped within the preset phase zeroing range, the human-machine interaction module is also used to respond to the user trigger operation on the opening interlock interface and send an interlock state switching signal to the programmable logic controller. The programmable logic controller is also used to execute an interlocking state switching program according to the interlocking state switching signal, so as to deactivate or activate the safety interlocking protection of the opening position of the sampling shear.

[0013] Furthermore, the interlocking interface includes an interlocking release control and an interlocking engagement control; When the opening interlock release control is triggered, the human-machine interaction module is used to send a release command to the programmable logic controller to release the opening interlock protection, allowing the disc cutter operation to be performed when the sampling shear is not fully opened to the safe high position. When the opening interlocking input control is triggered, the human-machine interaction module sends an input command to the programmable logic controller to restore the opening interlocking protection and prevent the sampling shear from performing disc blade operation before it is fully opened to the safe high position.

[0014] Furthermore, the programmable logic controller is also connected to the motor module, which is connected to the crankshaft; the human-machine interface module is also loaded with a jog control interface. The human-computer interaction module is also used to respond to user-triggered operations on the jog control interface and send jog mode signals and jog control signals to the programmable logic controller. The programmable logic controller is also used to control the motor module to drive the crankshaft to rotate at a small angle according to the jog mode signal and the jog control signal.

[0015] Furthermore, the jog control interface includes: a local jog mode control, a remote jog mode control, a crankshaft remote increase button, and a crankshaft remote decrease button; When the local jog mode control is triggered, the programmable logic controller is used to respond to the local jog control command sent by the local control box set at the sampling shear equipment site, so as to control the rotation direction and speed of the crankshaft. When the remote jog mode control is triggered, the programmable logic controller is used to respond to the remote jog control command corresponding to the remote crankshaft increase button or the remote crankshaft decrease button, so as to control the rotation direction and speed of the crankshaft.

[0016] On the other hand, this application also provides a sampling shear crankshaft phase calibration method, applied to the sampling shear crankshaft phase calibration system as described in any of the foregoing embodiments, the method comprising: When the sampling shear stops within the preset phase zeroing range, the human-machine interaction module responds to the user-triggered operation on the crankshaft calibration interface and sends a calibration start signal to the programmable logic controller. When the programmable logic controller receives the calibration start signal, it executes an automatic calibration program based on the current encoder rotation angle value, calculates and updates the crankshaft calibration value used to compensate for phase accumulation error, and corrects the crankshaft logical phase recorded in the system based on the updated crankshaft calibration value, so that the crankshaft logical phase is synchronously aligned with the actual mechanical phase of the crankshaft.

[0017] Compared with the prior art, this application has the following advantages: The sampling shear crankshaft phase calibration system provided in this application includes a programmable logic controller (PLC) and a human-machine interface (HMI) module connected to each other. The HMI module is loaded with a crankshaft calibration interface, and the PLC is also connected to an encoder mounted on the crankshaft of the sampling shear. When the sampling shear stops within a preset phase zeroing range, the HMI module responds to user-triggered operations on the crankshaft calibration interface by sending a calibration start signal to the PLC. Upon receiving the calibration start signal, the PLC executes an automatic calibration program based on the current encoder rotation angle value, calculates and updates the crankshaft calibration value used to compensate for accumulated phase errors, and corrects the recorded crankshaft logical phase in the system based on the updated crankshaft calibration value to synchronize the crankshaft logical phase with the actual mechanical phase of the crankshaft. When the sampling shear stops within the preset phase zeroing range, it indicates that the actual mechanical phase of the crankshaft is basically at the top dead center. At this time, the system can automatically perform software calibration through a one-key trigger to realign the crankshaft logical phase with the actual mechanical phase of the crankshaft. This eliminates the need for manual intervention in the mechanical coupling, ensuring that the shear blade can reliably return to a safe and accurate starting position after each shutdown. This fundamentally eliminates the safety hazards, equipment damage, and maintenance costs caused by manual calibration, and significantly improves the stopping stability of the sampling shear after a change of direction and the reliability of the shearing process. Attached Figure Description

[0018] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0019] Figure 1 A structural block diagram of a sampling shear crankshaft phase calibration system provided in this application; Figure 2 A schematic diagram of the user interface of a human-computer interaction module provided in this application; Figure 3 One of the logic flow diagrams of an automatic calibration program within a programmable logic controller provided in this application; Figure 4 A second schematic diagram of the logic flow of an automatic calibration program within a programmable logic controller provided in this application; Figure 5 A schematic diagram of the logic flow of an interlocking state switching program for a programmable logic controller provided in this application; Figure 6 One of the logic flow diagrams of a jog control program within a programmable logic controller provided in this application; Figure 7 The second schematic diagram of the logic flow of a jog control program within a programmable logic controller provided in this application; Figure 8 The third schematic diagram of the logic flow of a jog control program within a programmable logic controller provided in this application; Figure 9 This is a schematic flowchart of a sampling shear crankshaft phase calibration method provided in this application. Detailed Implementation

[0020] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0021] In the description of this application, it should be noted that relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. The term "connection" should be interpreted broadly, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium.

[0022] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0023] As described in the background section, the original sampling shearing process was as follows: the steel plate was moved to the south side of the roller conveyor by the centering device, and then transported to the shearing station by the input roller conveyor. The shear blade cut in a "south-to-north" direction. This process relied on the centering device to achieve the centering and posture correction of the steel plate, ensuring a stable shearing trajectory and controllable shear quality. However, long-term operation practice showed that due to the limitations of the on-site equipment layout (especially the serious interference between the turning arm of the flipper and the centering device), the centering device was frequently damaged, resulting in an equipment utilization rate of less than 50% for a long time. In order to maintain the continuous operation of the production line, the factory eventually removed the centering device and instead used the turning arm of the flipper roller conveyor for simple limiting guidance, forcing the steel plate to enter only from the north side of the roller conveyor.

[0024] While the modification alleviated the pressure of equipment downtime, it caused a significant deviation of the shearing path from the original design. If the original "south-to-north" cutting direction was maintained, the north side of the steel plate would wobble and slip due to lack of effective support, leading to process abnormalities such as incomplete shearing, burrs, blade jamming, and even blade breakage. Therefore, the production line implemented an adaptive adjustment to the shearing direction—changing the cutting direction of the shear blade to "north-to-south." This adjustment was achieved by changing the excitation phase sequence of the drive motor, switching the crankshaft rotation direction from clockwise to counterclockwise, thus ensuring that the shear blade movement direction matched the north side's plate-feeding direction. However, the change in crankshaft rotation introduced a new critical defect: its stopping and positioning stability at the highest position (i.e., top dead center, corresponding to a phase angle of 0° or 360°) significantly decreased. In actual operation, an average of 1-2 instances occurred per shift where the crankshaft failed to accurately and reliably stop at top dead center, manifesting as phase drift, positional jitter, or inertial overshoot. This instability directly induces serious malfunctions such as blade slippage (the shear blade falls unexpectedly before reaching the top dead center), continuous shearing (a single control command triggers multiple shearing actions), and uncontrolled shearing damaging the steel plate, endangering equipment safety and sample pass rate. The current method is manual phase calibration: operators must manually rotate the mechanical coupling between the phase encoder and the crankshaft to forcibly correct the consistency between the encoder feedback value and the actual mechanical angle of the crankshaft. This operation is not only time-consuming and labor-intensive, but also causes frequent torque application, leading to coupling wear, keyway slippage, rivet shearing, and even coupling seizure, posing safety hazards and increasing maintenance costs and downtime.

[0025] Therefore, how to achieve high-precision, high-reliability automatic stopping and real-time phase correction of the sampling shear crankshaft at the top dead center (corresponding to a phase angle of 0° or 360°) after canceling the centering device and changing the shearing direction (changing the crankshaft rotation direction from clockwise to counterclockwise), fundamentally eliminating slippage, continuous shearing, and shearing abnormalities, and simultaneously eliminating the safety risks, equipment damage, and maintenance burden caused by manual on-site calibration, is a technical problem that urgently needs to be solved by those skilled in the art.

[0026] To resolve the above technical issues, please refer to Figure 1This application provides a sampling shear crankshaft phase calibration system, which includes a programmable logic controller (PLC) and a human-machine interface module (such as a WinCC interface) connected to each other. The human-machine interface module is loaded with a crankshaft calibration interface, and the PLC is also connected to an encoder, which is mounted on the crankshaft of the sampling shear.

[0027] When the sampling shear stops within the preset phase zeroing range, the human-machine interface module responds to the user-triggered operation on the crankshaft calibration interface and sends a calibration start signal to the programmable logic controller.

[0028] When a calibration start signal is received, the programmable logic controller (PLC) executes an automatic calibration procedure based on the current encoder rotation angle value, calculates and updates the crankshaft calibration value to compensate for phase accumulation error, and corrects the crankshaft logical phase recorded in the system based on the updated crankshaft calibration value so that the crankshaft logical phase is synchronized with the actual mechanical phase of the crankshaft.

[0029] It should be noted that the preset phase zeroing range refers to the automatic calibration triggering interval, based on the top dead center of the crankshaft (corresponding to a phase angle of 0° or 360°), allowing for a certain mechanical angular deviation. Understandably, the sampling shear blade is connected to the crankshaft via a crank-connecting rod mechanism. When the crankshaft rotates to the top dead center, the connecting rod pushes the shear blade to the highest point of its stroke. In the shearing cycle, the shear blade moves downwards from the top dead center (i.e., the sampling shear cuts from north to south) to complete the shearing, then returns to the top dead center to prepare for the next action. Therefore, the top dead center is the starting point and safe ending point of each shearing cycle, and a crucial phase reference for ensuring accurate blade positioning and avoiding malfunctions.

[0030] Based on the above design, when the sampling shear stops within the preset phase zeroing range, it indicates that the actual mechanical phase of the crankshaft is basically at the top dead center. At this time, the system can automatically perform software calibration through a one-key trigger to realign the crankshaft logical phase with the actual mechanical phase of the crankshaft. This eliminates the need for manual intervention in the mechanical coupling, ensuring that the shear blade can reliably return to a safe and accurate starting position after each shutdown. This fundamentally eliminates the safety hazards, equipment damage, and maintenance costs caused by manual calibration, and significantly improves the stopping stability of the sampling shear after a change of direction and the reliability of the shearing process.

[0031] Further, please refer to Figure 2 In one optional implementation, the crankshaft calibration interface includes: a calibration button, an encoder angle display area, and a crankshaft calibration value display area.

[0032] The calibration button is used to respond to a calibration command triggered by the user and send a calibration start signal to the programmable logic controller.

[0033] The encoder angle display area is used to display the encoder rotation angle value in real time.

[0034] The crankshaft calibration value display area is used to display the crankshaft calibration value in real time.

[0035] Understandably, when the sampling shear stops and its crankshaft is within the preset phase zeroing range, the operator only needs to click the calibration button to trigger the programmable logic controller to execute the automatic calibration program, automatically completing the phase zeroing and meeting the shearing readiness conditions. This operation is simple, fast, and accurate, improving work efficiency while ensuring safety and reliability. It eliminates the need for maintenance personnel to perform manual mechanical calibration at the sampling shear site, effectively reducing equipment failure rates and allowing the equipment's effective operating rate to be stably increased to 98%.

[0036] For a better understanding, please refer to Figure 3 and Figure 4 In this embodiment of the application, the automatic calibration program in the programmable logic controller includes a first subtraction function block, a second subtraction function block, and an addition function block.

[0037] The first subtraction function block is used to subtract a preset angle value from the current encoder rotation angle value when the rising edge of the calibration start signal is received, so as to obtain the updated crankshaft calibration value.

[0038] The second subtraction function block is used to subtract the current encoder rotation angle value from 360° to obtain the angle deviation value.

[0039] The addition function block is used to add the angle deviation value to the updated crankshaft calibration value to obtain the corrected crankshaft logic phase.

[0040] In one optional implementation, the automatic calibration procedure further includes a multiplication function block and a first transmission function block. The multiplication function block multiplies the cumulative number of pulses sent by the encoder by the encoder angle conversion coefficient to obtain the encoder rotation angle value. The first transmission function block transmits the encoder rotation angle value to a first subtraction function block.

[0041] In another alternative implementation, the automatic calibration procedure further includes a first comparison function block, a second comparison function block, a second transfer function block, and a third subtraction function block.

[0042] The first comparison function block sends an enable signal to the second transmission function block when the corrected crankshaft logic phase is less than or equal to 360°. The second transmission function block, upon receiving the enable signal, uses the corrected crankshaft logic as the final crankshaft logic phase.

[0043] The second comparison function block sends an enable signal to the third subtraction function block when the corrected crankshaft logic phase is greater than 360°. The third subtraction function block, upon receiving the enable signal, subtracts 360° from the corrected crankshaft logic phase to obtain the final crankshaft logic phase.

[0044] Therefore, this application proposes a sampling shear crankshaft phase self-calibration system based on software closed-loop compensation for crankshaft steering change scenarios. Its core lies in: through the human-machine interface trigger mechanism and the digital calibration logic composed of PLC built-in function blocks, the dynamic alignment of the crankshaft logical phase with the top dead center mechanical reference is achieved without relying on the physical adjustment of the mechanical coupling. In particular, for problems such as stopping instability, phase drift and cumulative error amplification caused by canceling the centering device, using the north side single-sided feed plate and changing the shearing direction (crankshaft rotation from clockwise to counterclockwise), this application constructs a phase calibration system with engineering robustness, operational safety and process adaptability through a four-fold mechanism of "preset zeroing range + one-key trigger + angle deviation compensation + phase calibration zeroing". This not only fundamentally avoids coupling damage and personal risks caused by manual calibration, but also significantly improves the start-stop reliability and shearing repeatability of the shearing equipment, and greatly improves the effective operation rate of the sampling shear.

[0045] However, in actual operation, it was found that due to factors such as motor inertia, braking response delay, and load fluctuations, the sampling shear cannot always reliably stop within the preset phase zeroing range (i.e., the crankshaft mechanical phase does not enter the allowable deviation range centered on the 0° / 360° top dead center). When the stopping position deviates from this range (e.g., stopping near 180°), the shear blade is in a semi-closed or not fully open state, which not only fails to meet the shearing readiness conditions but also causes the system to refuse to execute subsequent actions due to the safety interlock mechanism. If the shearing parameters are forcibly adjusted at this time, data miscalibration, control logic conflicts, or even equipment malfunctions will occur due to the inaccuracy of the mechanical position. Traditional handling methods require on-site intervention by an electrician to disengage the interlock through manual cranking, which is complex, time-consuming, and poses safety hazards.

[0046] In view of this, in an alternative implementation, the human-machine interaction module is also loaded with an open interlock interface to provide a controlled, traceable safety intervention channel in non-standard shutdown states.

[0047] When the sampling shear is not stopped within the preset phase zeroing range, the human-machine interaction module is also used to respond to user-triggered operations on the opening interlock interface and send an interlock state switching signal to the programmable logic controller.

[0048] The programmable logic controller is also used to execute an interlocking state switching program based on the interlocking state switching signal to deactivate or activate the safety interlocking protection of the open position of the sampling shear.

[0049] Specifically, the interlocking interface includes an interlocking release control and an interlocking engagement control.

[0050] When the opening interlock release control is triggered, the human-machine interface module sends a release command to the programmable logic controller to release the opening interlock protection, allowing the disc cutter operation to be performed when the sampling shear is not fully opened to the safe high position.

[0051] When the opening interlock input control is triggered, the human-machine interface module sends an input command to the programmable logic controller to restore the opening interlock protection and prevent the sampling shear from performing disc knife operation before it is fully opened to the safe high position.

[0052] For example, please refer to Figure 5 When the operator clicks the release control on the interface, the release variable M839.0 in the PLC program takes effect, causing the comparison function block (CMP <= R) less than or equal to 180° to be shorted, thereby releasing the release interlock protection and allowing subsequent blade operation to be performed under the condition that the blade is not fully open, so as to bring the blade to the safe zero position.

[0053] As can be seen, by adding an interlocking interface and corresponding interlocking status switching function, this application enables operators to selectively release or restore safety interlocks in the interface when the sampling shear stops abnormally, based on the actual situation. This allows for safe and flexible equipment reset or fault handling, effectively avoiding the complex process and safety risks of traditional manual on-site intervention, and significantly improving the system response speed and operational controllability under abnormal operating conditions.

[0054] In addition, if emergency shear lifting or handling is required during the production shearing process, in order to prevent slippage accidents, the sampling shear crankshaft phase calibration system provided in this application provides convenient remote operation functions through PLC program optimization and human-machine interface, eliminating the need for personnel to go to the H4 local control box for jogging operation.

[0055] Specifically, in one optional implementation, the programmable logic controller is also connected to the motor module, the motor module is connected to the crankshaft, and the human-machine interface module is also loaded with a jog control interface.

[0056] The human-machine interaction module is also used to respond to user-triggered operations on the jog control interface and send jog mode signals and jog control signals to the programmable logic controller.

[0057] The programmable logic controller is also used to control the motor module to drive the crankshaft to perform small-angle rotation based on the jog mode signal and the jog control signal.

[0058] Furthermore, the jog control interface includes: local jog mode control, remote jog mode control, crankshaft remote increase button, and crankshaft remote decrease button.

[0059] When the local jog mode control is triggered, the programmable logic controller responds to the local jog control command sent by the local control box set at the sampling shear equipment site to control the rotation direction and speed of the crankshaft.

[0060] When the remote jog mode control is triggered, the programmable logic controller responds to the remote jog control command corresponding to the crankshaft remote increase or remote decrease button to control the rotation direction and speed of the crankshaft.

[0061] Therefore, this application completely migrates the crankshaft jogging operation, which originally needed to be performed at the H4 local control box on the sampling shear equipment, to the human-machine interface, constructing a safe, precise, and remotely operable fine-tuning and emergency blade lifting control system. In actual production, when there is a sudden risk of blade slippage or when the shear blade position needs to be temporarily adjusted, the operator does not need to go to the site to open the H4 control box or manually operate the panel buttons. They only need to complete the mode switching and command triggering on the human-machine interface of the central control panel to achieve millidegree-level small angle adjustment of the crankshaft.

[0062] For example, please refer to Figures 6 to 8 The system, through PLC program logic refactoring, introduces a remote enabling mechanism into the original local jog control loop: a new variable M590.4 is added as a "remote jog enable flag," whose state is synchronized in real time by the mode switching switch on the HMI; simultaneously, the control logic that originally only responded to local input points I22.1 (local mode selection), I22.4 (local jog increase), and I22.5 (local jog decrease) is transformed into a dual-channel parallel judgment structure—that is, the PLC simultaneously monitors local and remote signals and dynamically enables the corresponding channel based on the true / false state of M590.4: when M590.4 = 1 (remote mode enabled), the PLC ignores I22.1, I22.4, and I22.5, and instead uses the remote variables M590.2 (crankshaft remote increase) and M590.3 (crankshaft remote decrease) mapped by the HMI as the effective jog command source; when M590.4 = 1, the remote mode enable flag is activated ... When the value is 0, it will automatically revert to the traditional local operation mode, ensuring a seamless transfer of control without any loss of functionality.

[0063] At the level of human-computer interaction, such as Figure 2As shown, the jog control interface features intuitive visual controls: a two-way sliding mode switch (pull up for "remote screen jog," pull down for "local operation"), and a pair of transient buttons with anti-accidental touch design—"remote crankshaft increase" and "remote crankshaft decrease," corresponding to the rising edge triggering of M590.2 and M590.3, respectively. Each click is processed by the PLC's internal pulse processing, outputting a jog pulse with controllable duration (e.g., 200ms) and limited amplitude (e.g., single drive ≤0.5° mechanical angle). This drives the motor module to rotate the crankshaft precisely and reversibly at small angles, thereby achieving millimeter-level online correction of the shear blade position.

[0064] In summary, the sampling shear crankshaft phase calibration system provided in this application integrates three functions—crankshaft calibration, opening interlock, and jog control—into a single human-machine interface, thereby achieving unified and remote control and status monitoring of the sampling shear equipment. Specifically, the human-machine interface module is loaded with three operation entry points: calibration, interlock, and jog, allowing operators to complete remote command issuance and status monitoring within a single screen. The programmable logic controller (PLC), as the system control core, can execute corresponding phase compensation calculations, crankshaft logic phase calibration, interlock status switching, and local / remote jog discrimination control based on received commands. This sampling shear crankshaft phase calibration system reconstructs the control mode of the sampling shear: it unifies and elevates multiple key operations, originally scattered across local control boxes, encoder terminals, PLC program blocks, and paper-based work instructions, to a visualized, programmable, and traceable digital interactive level, realizing the de-site and de-professional transformation of sampling shear operations and effectively improving shearing efficiency and operational reliability.

[0065] Based on the above system design, in one optional implementation, this application also provides a sampling shear crankshaft phase calibration method, which is applied to the sampling shear crankshaft phase calibration system as described in any of the foregoing embodiments. Specifically, please refer to... Figure 9 The sampling and shearing crankshaft phase calibration method includes the following steps: In step S100, when the sampling shear stops within the preset phase zeroing range, the human-machine interaction module responds to the user-triggered operation on the crankshaft calibration interface and sends a calibration start signal to the programmable logic controller.

[0066] In step S200, when the programmable logic controller receives the calibration start signal, it executes an automatic calibration program based on the current encoder rotation angle value, calculates and updates the crankshaft calibration value used to compensate for phase accumulation error, and corrects the crankshaft logical phase recorded in the system based on the updated crankshaft calibration value so that the crankshaft logical phase is synchronously aligned with the actual mechanical phase of the crankshaft.

[0067] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

[0068] It will be apparent to those skilled in the art that this application is not limited to the details of the exemplary embodiments described above, and that this application can be implemented in other specific forms without departing from the spirit or essential characteristics of this application. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this application is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this application. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A sampling shear crankshaft phase calibration system, characterized in that, It includes a programmable logic controller and a human-machine interface module connected together; the human-machine interface module is loaded with a crankshaft calibration interface, and the programmable logic controller is also connected to an encoder, which is mounted on the crankshaft of the sampling shear. When the sampling shear stops within the preset phase zeroing range, the human-machine interaction module is used to respond to the user-triggered operation on the crankshaft calibration interface and send a calibration start signal to the programmable logic controller. When the calibration start signal is received, the programmable logic controller is used to execute an automatic calibration program based on the current encoder rotation angle value, calculate and update the crankshaft calibration value used to compensate for phase accumulation error, and correct the crankshaft logical phase recorded in the system based on the updated crankshaft calibration value, so that the crankshaft logical phase is synchronously aligned with the actual mechanical phase of the crankshaft.

2. The sampling shear crankshaft phase calibration system according to claim 1, characterized in that, The automatic calibration program in the programmable logic controller includes a first subtraction function block, a second subtraction function block, and an addition function block; The first subtraction function block is used to subtract a preset angle value from the current encoder rotation angle value when the rising edge of the calibration start signal is received, so as to obtain the updated crankshaft calibration value. The second subtraction function block is used to subtract the current encoder rotation angle value from 360° to obtain the angle deviation value; The addition function block is used to add the angle deviation value to the updated crankshaft calibration value to obtain the corrected crankshaft logic phase.

3. The sampling shear crankshaft phase calibration system according to claim 2, characterized in that, The automatic calibration program also includes a multiplication function block and a first transfer function block; The multiplication function block is used to multiply the cumulative number of pulses sent by the encoder by the encoder angle conversion coefficient to obtain the encoder rotation angle value; The first transmission function block is used to transmit the encoder rotation angle value to the first subtraction function block.

4. The sampling shear crankshaft phase calibration system according to claim 2, characterized in that, The automatic calibration program also includes a first comparison function block, a second comparison function block, a second transmission function block, and a third subtraction function block; The first comparison function block is used to send an enable signal to the second transmission function block when the corrected crankshaft logic phase is less than or equal to 360°; the second transmission function block is used to take the corrected crankshaft logic as the final crankshaft logic phase when it receives the enable signal. The second comparison function block is used to send an enable signal to the third subtraction function block when the corrected crankshaft logic phase is greater than 360°; the third subtraction function block is used to subtract 360° from the corrected crankshaft logic phase when the enable signal is received to obtain the final crankshaft logic phase.

5. The sampling shear crankshaft phase calibration system according to claim 1, characterized in that, The crankshaft calibration interface includes: a calibration button, an encoder angle display area, and a crankshaft calibration value display area; The calibration button is used to respond to a calibration command triggered by the user and send the calibration start signal to the programmable logic controller; The encoder angle display area is used to display the encoder rotation angle value in real time; The crankshaft calibration value display area is used to display the crankshaft calibration value in real time.

6. The sampling shear crankshaft phase calibration system according to claim 1, characterized in that, The human-computer interaction module also loads an interlocking interface; When the sampling shear is not stopped within the preset phase zeroing range, the human-machine interaction module is also used to respond to the user trigger operation on the opening interlock interface and send an interlock state switching signal to the programmable logic controller. The programmable logic controller is also used to execute an interlocking state switching program according to the interlocking state switching signal, so as to deactivate or activate the safety interlocking protection of the opening position of the sampling shear.

7. The sampling shear crankshaft phase calibration system according to claim 6, characterized in that, The interlocking interface includes an interlocking release control and an interlocking engagement control; When the opening interlock release control is triggered, the human-machine interaction module is used to send a release command to the programmable logic controller to release the opening interlock protection, allowing the disc cutter operation to be performed when the sampling shear is not fully opened to the safe high position. When the opening interlocking input control is triggered, the human-machine interaction module sends an input command to the programmable logic controller to restore the opening interlocking protection and prevent the sampling shear from performing disc blade operation before it is fully opened to the safe high position.

8. The sampling shear crankshaft phase calibration system according to claim 1, characterized in that, The programmable logic controller is also connected to the motor module, which is connected to the crankshaft; the human-machine interface module is also loaded with a jog control interface. The human-computer interaction module is also used to respond to user-triggered operations on the jog control interface and send jog mode signals and jog control signals to the programmable logic controller. The programmable logic controller is also used to control the motor module to drive the crankshaft to rotate at a small angle according to the jog mode signal and the jog control signal.

9. The sampling shear crankshaft phase calibration system according to claim 8, characterized in that, The jog control interface includes: a local jog mode control, a remote jog mode control, a crankshaft remote increase button, and a crankshaft remote decrease button; When the local jog mode control is triggered, the programmable logic controller is used to respond to the local jog control command sent by the local control box set at the sampling shear equipment site, so as to control the rotation direction and speed of the crankshaft. When the remote jog mode control is triggered, the programmable logic controller is used to respond to the remote jog control command corresponding to the remote crankshaft increase button or the remote crankshaft decrease button, so as to control the rotation direction and speed of the crankshaft.

10. A sampling shear crankshaft phase calibration method, characterized in that, The method, applied to the sampling shear crankshaft phase calibration system as described in any one of claims 1-9, comprises: When the sampling shear stops within the preset phase zeroing range, the human-machine interaction module responds to the user-triggered operation on the crankshaft calibration interface and sends a calibration start signal to the programmable logic controller. When the programmable logic controller receives the calibration start signal, it executes an automatic calibration program based on the current encoder rotation angle value, calculates and updates the crankshaft calibration value used to compensate for phase accumulation error, and corrects the crankshaft logical phase recorded in the system based on the updated crankshaft calibration value, so that the crankshaft logical phase is synchronously aligned with the actual mechanical phase of the crankshaft.

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