Pccp centrifuge and feeder linkage energy-saving control system and method

Abstract

The present application relates to a kind of PCCP centrifuge and feeding machine linkage energy-saving control system and method, it is related to prestressed steel cylinder concrete pipe manufacturing and automation control technical field, the system in the present application includes feeding machine unit, centrifuge unit, linkage controller and man-machine interaction unit.Linkage controller determines real-time feeding state according to cumulative feeding amount and material position, and it is compared with target feeding curve, obtains progress deviation and current material stage, generates centrifuge target speed under stage speed interval and stage switching rule constraint;When progress deviation exceeds preset range, at least one of feeding machine and centrifuge is executed compensation control;Feeding is completed, and centrifugal compaction operation is maintained, and deceleration shutdown is reached after reaching preset compaction condition.The present application can reduce energy consumption, improve concrete material uniformity, compaction and product consistency.

Description

Technical Field

[0001] This invention belongs to the field of prestressed steel cylinder concrete pipe manufacturing and automation control technology, and in particular relates to an energy-saving control system and method for the linkage of PCCP centrifuge and feeder. Background Technology

[0002] In the production of PCCP cores, small-diameter products typically employ a centrifugal molding process to complete concrete placement and compaction. During production, a feeder conveys and spreads concrete along the axial direction of a rotating mold, while a centrifuge drives the mold to rotate, causing the concrete to gradually distribute, level, and compact under centrifugal force. This process is highly sensitive to the matching relationship between the feeding rhythm and the centrifugal speed; the proper coordination between the two directly affects production energy consumption, concrete distribution, and the quality of the finished core.

[0003] In current small-diameter PCCP centrifugal molding production, the feeder and centrifuge mostly use independent control methods. Operators typically pre-set the centrifuge's speed curves for slow material distribution, medium-speed uniform distribution, and high-speed compaction stages based on experience, and then coordinate with the feeder for production. This method has the following problems: First, there is a lack of real-time linkage between the feeding progress and the centrifugal acceleration process. When the feeding is delayed, the centrifuge is prone to idling, waiting, or ineffective acceleration, leading to increased power consumption. When the feeding is ahead of schedule, the high-speed stage may start prematurely, causing load fluctuations and energy waste. Second, uneven feeding or a mismatch between the feeding process and the centrifugal speed can easily lead to localized material accumulation, thin material, stratification, segregation, and fluctuations in the inner wall quality, affecting the core's compactness, impermeability, and durability. Third, the existing control method is highly dependent on operator experience, resulting in poor quality and energy consumption stability under different shifts and operating conditions, making it difficult to achieve standardized and automated control.

[0004] Therefore, it is necessary to provide a PCCP centrifuge and feeder linkage energy-saving control system and method, which can determine the matching relationship between the feeding process and the centrifugation process in real time based on the cumulative feeding amount, material placement position and centrifuge operating status, and adjust the feeder and centrifuge accordingly to reduce energy consumption in the centrifugal molding process and improve the uniformity, density and consistency of concrete placement. Summary of the Invention

[0005] The purpose of this invention is to address the problems of high energy consumption, large product quality fluctuations, and strong reliance on operator experience in existing small-diameter PCCP centrifugal molding processes, which typically involve independent control of the feeder and centrifuge. This invention provides a PCCP centrifugal molding linkage control system and method. The system and method use the real-time status of the feeding process as the basis for adjusting the centrifugal process, and, when necessary, perform reverse compensation control on the feeding process. This ensures that the feeding process and the centrifugal molding process remain coordinated, reducing the overall energy consumption of the centrifugal process while improving the uniformity, density, and consistency of the concrete distribution.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: This invention provides a PCCP centrifugal molding linkage control system, including a feeder unit, a centrifuge unit, a linkage controller, and a human-machine interface unit. The feeder unit includes a conveying mechanism for feeding concrete into the mold, a feed driver for driving the conveying mechanism, a feed metering component for detecting the cumulative feed amount, and a position detection component for detecting the axial position of the spreading mechanism along the mold. The centrifuge unit includes the mold, a centrifugal drive motor for driving the mold's rotation, a centrifugal driver connected to the centrifugal drive motor, and a speed detection component for detecting the actual rotational speed of the mold. The human-machine interface unit is used to input mold shape parameters and concrete process parameters. The linkage controller is connected to the feed driver, the feed metering component, the position detection component, the centrifugal driver, the speed detection component, and the human-machine interface unit, and stores target feeding curves, stage speed ranges, stage switching rules, and deviation compensation rules corresponding to different mold shape parameters and concrete process parameters.

[0007] Preferably, the linkage controller is used to determine the real-time feeding status based on the cumulative feeding amount and the placement position. The real-time feeding status includes not only the total feeding progress but also the filling status of different areas along the axial direction of the pipe mold. Further, the linkage controller can divide the inner cavity of the pipe mold into multiple placement zones along the axial direction based on the detection results of the position detection component, and determine the filling status of each placement zone by combining the cumulative feeding amount or the feeding increment per unit time at each moment, so as to reflect the actual distribution of concrete in the pipe mold.

[0008] Preferably, the linkage controller is used to determine the progress deviation and the current feeding stage based on the comparison between the real-time feeding status and the target feeding curve, and to generate the centrifuge target speed under the constraints of the stage speed range and stage switching rules. The progress deviation is used to characterize the degree to which the current actual feeding progress is ahead or behind the target feeding progress; the current feeding stage may include the initial feeding stage, the main filling stage, the final leveling stage, and the compaction stage after feeding is completed. By limiting the centrifuge target speed within the allowable speed range of the corresponding stage, material flying or segregation caused by excessive speed in the early stage of feeding can be avoided, and the leveling and compaction effects can be avoided due to insufficient speed increase in the later stage.

[0009] Furthermore, when the progress deviation exceeds a preset range, the linkage controller performs compensation control on at least one of the feeding driver and centrifugal driver according to the deviation compensation rule, so as to keep the feeding process synchronized with the centrifugation process. Specifically, when the progress deviation indicates feeding lag, the linkage controller can perform at least one of the following controls: maintaining the current speed of the centrifuge, reducing the centrifuge acceleration slope, increasing the feeder speed, or increasing the operating speed of the fabric spreading mechanism; when the progress deviation indicates feeding ahead, the linkage controller can perform at least one of the following controls: limiting the feeder speed, limiting the operating speed of the fabric spreading mechanism, executing the next stage speed control in advance, or limiting the upper limit of the target speed for the next stage. Thus, the present invention does not only adjust the centrifuge unidirectionally according to the feeding state, but forms a bidirectional coordinated adjustment of the feeder and the centrifuge.

[0010] Furthermore, the linkage controller can also acquire the operating parameters of the feeding driver and the centrifugal driver to identify abnormal operating conditions such as material blockage, material interruption, idling, slippage, abnormal speed tracking, or local material accumulation. After identifying the abnormal operating conditions, it can execute at least one of the following controls: speed maintenance, speed reduction, speed limiting, shutdown, or alarm control, in order to improve the system's operational stability and production safety.

[0011] Furthermore, the linkage controller can record the actual feeding curve, actual speed curve, energy consumption data, and corresponding finished product quality data for each production process, and correct the target feeding curve, stage speed range, and deviation compensation rules corresponding to the same specification of pipe type based on the recording results, thereby gradually improving the control matching and energy consumption control effect of subsequent production tasks.

[0012] This invention also provides a PCCP centrifugal molding linkage control method based on the above system, comprising: inputting the pipe type parameters and concrete process parameters corresponding to the current production task; retrieving the corresponding target feeding curve, stage speed range, stage switching rules, and deviation compensation rules; collecting the cumulative feeding amount, material placement position, and actual centrifuge speed to determine the real-time feeding status; comparing the real-time feeding status with the target feeding curve to obtain the progress deviation, and determining the current material placement stage based on the real-time feeding status; generating the centrifuge target speed under the constraints of the stage speed range and stage switching rules; when the progress deviation is outside the preset range, correcting at least one of the feeder speed, material placement mechanism running speed, and centrifuge acceleration rhythm according to the deviation compensation rules; performing closed-loop speed regulation control based on the centrifuge target speed and the centrifuge actual speed; maintaining centrifugal compaction operation after feeding is completed, and controlling the centrifuge to decelerate and stop after reaching the preset compaction condition, while recording the production process data.

[0013] Through the above system and method, the present invention organically combines feeding progress, material placement position, centrifugal speed and stage control, so that centrifugal molding control is transformed from traditional fixed-time control to linkage control based on real-time feeding status, which can better adapt to the production requirements of different pipe specifications and different concrete process conditions.

[0014] Compared with the prior art, the energy-saving control system and method for the linkage between a PCCP centrifuge and a feeder described in this invention have the following advantages: (1) Compared with the prior art, the present invention does not simply control the centrifuge speed according to the preset time curve, but determines the real-time feeding state based on the cumulative feeding amount and the material distribution position, and generates the centrifuge target speed based on the real-time feeding state. Therefore, the centrifuge speed can be better matched with the actual material distribution process, and reduce the energy waste caused by the centrifuge running idle, waiting or ineffective speed increase when the feeding is delayed. (2) When the progress deviation exceeds the preset range, the present invention can not only adjust the speed-up rhythm of the centrifuge, but also compensate for the speed of the feeder or the running speed of the feeding mechanism, forming a two-way coordinated adjustment relationship between the feeder and the centrifuge. Through this linkage method, the problems of feeding ahead, feeding behind, and stage switching mismatch that occur in the traditional independent control mode can be reduced, and the coordination of the entire centrifugal forming process can be improved; (3) This invention divides the inner cavity of the pipe mold into multiple material distribution zones along the axial direction, and determines the filling state of each material distribution zone by combining the material distribution position and the cumulative feeding amount. This allows for a more detailed judgment on the uniformity of concrete distribution within the pipe mold. Constraining the stage switching and acceleration process based on the zone filling state helps to avoid local material accumulation, local material thinning, stratification, and segregation, thereby improving the density and uniformity of concrete and the quality of the inner wall of the pipe core. (4) The present invention has set up an abnormal working condition identification and handling mechanism for material blockage, material interruption, idling, slippage, abnormal speed tracking, etc. When an abnormality occurs, it can perform control actions such as speed maintenance, speed reduction, speed limit, shutdown or alarm, thereby improving the system operation stability, reducing the adverse effects of abnormal working conditions on equipment and product quality, and enhancing the reliability of engineering applications. (5) This invention can record the actual feeding curve, actual speed curve, energy consumption data and finished product quality data, and correct the target feeding curve, stage speed range and deviation compensation rules corresponding to the same specification tube type, so that the system has continuous optimization capabilities. With the accumulation of production data, the system has stronger adaptability to different working conditions, which is conducive to further reducing energy consumption and improving product consistency; (6) The structure of the present invention is clear and the control logic is well-defined. It is suitable for the automation transformation of small-diameter PCCP centrifugal molding and is also easy to implement in conjunction with existing centrifuges, feeders, PLC control systems and human-machine interfaces. It has good industrial application value. Attached Figure Description

[0015] 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 control method logic described in an embodiment of the present invention; Figure 2 This is a schematic diagram of the overall architecture of the system described in an embodiment of the present invention; Figure 3 This is a schematic diagram of the control method described in an embodiment of the present invention. Detailed Implementation

[0016] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0017] 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.

[0018] 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.

[0019] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] This embodiment takes the production of PCCP cores with a diameter of DN800 and an effective length of 5000mm as an example, with a concrete design strength of C50. The feeding unit adopts a screw conveyor method, and the feeding metering component uses an incremental rotary encoder mounted on the feeding screw drive shaft. The position detection component is used to detect the running position of the material distribution mechanism along the pipe mold axis. The linkage controller is implemented using a programmable control unit, and the centrifuge unit is driven by a variable frequency motor. The centrifuge driver receives the speed setting command output by the linkage controller, and the speed detection component provides real-time feedback on the actual speed of the centrifuge. The human-machine interface unit is used to complete product model selection, parameter input, curve display, data recording, and alarm management.

[0021] In one embodiment, a PCCP centrifugal molding linkage control system includes a feeder unit, a centrifuge unit, a linkage controller, and a human-machine interface unit. The feeder unit includes a conveying mechanism, a feed driver, a feed metering component, and a position detection component. The conveying mechanism can be a screw conveyor, a belt conveyor, or other mechanisms suitable for conveying concrete into the mold. The feed driver drives the conveying mechanism. The feed metering component detects the cumulative feed amount and can be one or more of an encoder, a weighing sensor, and a level sensor. The position detection component detects the running position of the material distribution mechanism along the mold axis and can be a position encoder, a limit switch, a proximity switch, or other position detection elements.

[0022] The centrifuge unit includes a tube mold, a centrifugal drive motor, a centrifugal actuator, and a speed detection component. The centrifugal drive motor drives the tube mold to rotate. The centrifugal actuator, connected to the centrifugal drive motor, receives speed control commands from the linkage controller and adjusts the operating state of the centrifugal drive motor. The speed detection component detects the actual speed of the tube mold in real time and can be a speed encoder, speed sensor, or other speed detection device.

[0023] The linkage controller is preferably implemented using a PLC, industrial control computer, or other programmable control unit. The human-machine interface unit is used to input the pipe type parameters and concrete process parameters corresponding to the current production task, and displays the cumulative feeding amount, real-time feeding progress, material placement position, centrifuge speed, alarm information, and historical data retrieval results. The pipe type parameters may include pipe diameter, length, wall thickness, etc., and the concrete process parameters may include mix designation number, slump category, target total feeding amount, etc.

[0024] In this embodiment, the linkage controller pre-stores target feeding curves, stage speed ranges, stage switching rules, and deviation compensation rules corresponding to different pipe type parameters and concrete process parameters. The target feeding curve characterizes the target feeding progress of a production task under normal operating conditions over time. The stage speed range defines the permissible operating speed range of the centrifuge at different feeding stages. The stage switching rules specify the conditions that the centrifuge must meet to switch from one feeding stage to another. The deviation compensation rules specify the compensating actions that the feeder and centrifuge should take when the actual feeding state deviates from the target feeding state.

[0025] To more accurately reflect the actual distribution of concrete within the formwork, the linkage controller divides the formwork cavity axially into multiple placement zones based on the detection results from the position detection component. Each placement zone corresponds to a specific axial length. The linkage controller combines the cumulative feeding amount, the feeding increment per unit time, and the current position of the placement mechanism to determine the filling state of each placement zone. This filling state indicates the degree of concrete filling or the relative distribution level within the corresponding placement zone. By simultaneously considering the total feeding progress and the filling state of each placement zone, the linkage controller can generate a real-time feeding status that more closely reflects actual working conditions.

[0026] In this embodiment, the preset uniformity condition is used to characterize that the concrete distribution in each placing zone has reached a state suitable for stage switching or continued acceleration. The preset uniformity condition is not based on a single parameter, but is determined comprehensively by combining multiple judgment factors. These factors include at least: whether the difference in filling state between each placing zone is within the allowable range, whether the filling change between adjacent placing zones is gradual, whether the current total feeding progress matches the current position of the placing mechanism, and whether there are localized material accumulations, localized thin materials, or obvious discontinuous distributions. When the linkage controller determines that the filling state of each placing zone meets the above comprehensive conditions, it considers the zone filling state to have reached the preset uniformity condition and allows the corresponding stage switching or acceleration control to be executed; if the preset uniformity condition is not met, the stage switching is delayed and the operating speed of the feeder, placing mechanism, or centrifuge acceleration rhythm is continuously coordinated and adjusted to make the concrete distribution in the pipe mold axis tend to be uniform.

[0027] Before production begins, operators input the pipe type parameters and concrete process parameters corresponding to the current production task through the human-machine interface unit. The linkage controller retrieves the corresponding target feeding curve, stage speed range, stage switching rules, and deviation compensation rules based on the input parameters, and completes the initialization settings.

[0028] In this embodiment, after the operator selects the DN800×5000 product model on the human-machine interface unit, the system automatically loads the corresponding preset process parameters, where the total theoretical feed amount Q_total is 2.8 cubic meters and the target feeding time T_target is 420 seconds. The target progress curve P_target(t) under ideal uniform feeding conditions is: P_target(t)=(t / T_target)×100%; Where t is the current time since the start of the self-feeding start timer. The linkage controller compares the target progress curve with the real-time feeding progress to determine whether the current feeding progress is ahead or behind.

[0029] Subsequently, the feeder unit begins to deliver concrete into the mold, and the centrifuge unit begins to drive the mold to rotate.

[0030] During production, the feeding metering component continuously collects the cumulative feeding amount, the position detection component continuously collects the axial position of the fabric spreading mechanism, and the speed detection component continuously collects the actual speed of the centrifuge. The linkage controller determines the total feeding progress based on the cumulative feeding amount and, in conjunction with the fabric spreading position, allocates the current feeding amount to the corresponding fabric spreading zones to determine the filling status of each fabric spreading zone.

[0031] In this embodiment, the cumulative feed amount Q_actual is calculated based on the cumulative number of encoder pulses, and its calculation formula is as follows: Q_actual=(C_pulse / R_enc)×q0; Where C_pulse is the cumulative number of encoder pulses, R_enc is the number of pulses per encoder revolution, and q0 is the theoretical conveying capacity per revolution of the feeding mechanism. In this embodiment, R_enc is taken as 1000 pulses / revolution, and q0 is calibrated to 0.005 cubic meters / revolution. Based on the cumulative feeding amount, the total feeding progress P can be further obtained, and its calculation formula is: P = (Q_actual / Q_total) × 100%; Where Q_total is the total theoretical feed amount corresponding to the current production task.

[0032] Here, the real-time feeding status includes at least the overall feeding progress and the zone filling status. The linkage controller compares the real-time feeding status with the target feeding curve to obtain the progress deviation, and determines the current material placement stage based on the real-time feeding status.

[0033] In one alternative implementation, the current fabric laying stage includes an initial fabric laying stage, a main body filling stage, a final leveling stage, and a compaction stage after the feeding is completed.

[0034] In this embodiment, the reference centrifugal speed curve N_base(P) is set in segments according to the feeding progress P. Specifically, when P is between 0% and 15%, it is the initial material distribution stage, and the reference speed is controlled between 80 rpm and 120 rpm to reduce the risk of material spillage and ensure that the concrete evenly covers the bottom of the formwork; when P is between 15% and 85%, it is the main filling stage, and the reference speed is controlled between 120 rpm and 380 rpm, gradually increasing as the material volume increases, so as to realize the synchronous operation of the material distribution process and the compaction process; when P is between 85% and 100%, it is the final leveling stage, and the reference speed is controlled between 380 rpm and 420 rpm to improve the inner wall forming quality; after the feeding is completed, it enters the constant speed compaction stage, and the centrifuge runs at 420 rpm for 3 minutes to further compact and form the concrete.

[0035] The initial feeding stage corresponds to the period when concrete just enters the formwork and is sensitive to spillage and localized material buildup. At this stage, the centrifuge's target speed is limited to a low range. The main filling stage corresponds to the period when concrete continues to enter and gradually spreads. At this stage, the centrifuge's target speed can be gradually increased according to the feeding progress. The final leveling stage corresponds to the period when feeding is nearly complete and the inner wall forming quality needs optimization. At this stage, the centrifuge's target speed can be further increased, but it is still constrained by the upper limit of the allowable speed for the current stage. The compaction stage after feeding is completed corresponds to the stage where a certain speed is maintained after feeding stops to further compact and form the concrete.

[0036] The linkage controller generates the centrifuge target speed under the constraints of the stage speed range and stage switching rules.

[0037] In this embodiment, the linkage controller calculates the progress deviation ΔP based on the real-time feeding progress P at the current time t and the target progress P_target(t). The calculation formula is as follows: ΔP = P - P_target(t); To dynamically correct the reference speed based on the schedule deviation, a correction factor K is defined: K = 1 + α × ΔP; Where α is the progress sensitivity coefficient, and in this embodiment, α is taken as 0.3. When the feeding progress is ahead, ΔP is a positive value, and the correction factor K is greater than 1; when the feeding progress is behind, ΔP is a negative value, and the correction factor K is less than 1. Based on the correction factor, the corrected candidate rotational speed N_temp can be obtained: N_temp = K × N_base; Wherein, N_base is the reference speed obtained by looking up a table or interpolating from the preset reference centrifugal speed curve based on the current feeding progress P. The linkage controller then limits N_temp according to the allowable speed range corresponding to the current feeding stage to obtain the final centrifuge target speed N_set, so as to ensure that the centrifuge target speed is always within the allowable speed range of the current stage.

[0038] If the current real-time feeding status indicates that the filling status of each placement zone is not yet balanced, or that there is a tendency for localized material accumulation, the linkage controller will restrict the centrifuge from entering a higher speed stage, or reduce the current acceleration rate, to avoid localized instability in concrete distribution at high speeds. If the current real-time feeding status indicates that the filling status of each placement zone has reached the preset uniformity condition, the linkage controller will allow the execution stage switch. The preset uniformity condition can be determined based on one or more of the following: zone filling differences, differences between adjacent zones, and the degree of matching between overall progress and location.

[0039] When the progress deviation is within the preset range, the linkage controller controls the centrifuge to operate according to the target logic corresponding to the current material feeding stage. When the progress deviation exceeds the preset range, the linkage controller performs compensation control according to the deviation compensation rules.

[0040] In this embodiment, when |ΔP| is not greater than 5%, the linkage controller adjusts according to the conventional linkage logic of the current material feeding stage; when |ΔP| is greater than 5%, it is determined to be a large deviation condition, and deviation compensation control is activated. Specifically, when ΔP < -5%, it is determined to be a serious feeding delay, the linkage controller suspends the execution of the centrifuge speed-up logic, and keeps the centrifuge target speed N_set of the current control cycle at the set value of the previous control cycle until ΔP recovers to above -3% before continuing to increase the speed; when ΔP > +5%, it is determined to be a significant feeding advance, and the linkage controller allows the centrifuge target speed to approach the reference speed of the next stage in advance, provided that it does not exceed the upper limit speed of the current stage, in order to reduce the risk of local material accumulation caused by the mismatch between the material feeding process and the centrifugation process.

[0041] Specifically, when the progress deviation indicates feeding lag, the linkage controller can take at least one of the following measures: maintaining the current speed of the centrifuge, reducing the centrifuge acceleration slope, increasing the feeder speed, and increasing the operating speed of the material distribution mechanism, so that the actual feeding state gradually catches up with the target feeding state. When the progress deviation indicates feeding ahead of schedule, the linkage controller can take at least one of the following measures: limiting the feeder speed, limiting the operating speed of the material distribution mechanism, executing the next stage speed control in advance, and limiting the upper limit of the target speed for the next stage, to prevent premature material accumulation or stage mismatch. Thus, the feeder unit and the centrifuge unit form a bidirectional linkage control, rather than operating independently.

[0042] To ensure the centrifuge's stability in tracking the target speed, the linkage controller can also perform closed-loop speed regulation control based on the centrifuge's target speed and actual speed.

[0043] In this embodiment, the linkage controller compares the centrifuge target speed N_set with the centrifuge actual speed N_actual, and outputs a speed control signal using a PID closed-loop method primarily based on proportional regulation. This reduces speed tracking errors caused by load changes, equipment inertia, or transmission fluctuations. After the closed-loop regulation, the linkage controller converts the centrifuge target speed into an analog control signal recognizable by the driver and outputs it to the centrifuge driver, ensuring that the centrifuge actual speed stably tracks the target speed.

[0044] Specifically, the linkage controller compares the difference between the actual speed of the centrifuge and the target speed, and outputs a speed control signal to the centrifuge drive to eliminate speed tracking errors caused by load changes or equipment inertia. This allows the actual speed of the centrifuge to follow the target speed changes more smoothly, avoiding the adverse effects of sudden speed increases or decreases on the concrete distribution.

[0045] In another embodiment, the linkage controller is also connected to the operating parameter output terminals of the feeding driver and the centrifugal driver to acquire the feeding load signal and the centrifugal load signal. The linkage controller comprehensively judges whether there are abnormal operating conditions such as material blockage, material interruption, idling, slippage, abnormal speed tracking, or localized material accumulation based on the feeding metering component, position detection component, speed detection component, and driver operating parameters. When an abnormal operating condition is detected, the linkage controller executes at least one of the following controls: speed maintenance, speed reduction, speed limiting, shutdown, or alarm control. For example, when material blockage is detected, the centrifuge can be limited from continuing to increase speed and an alarm can be triggered; when material interruption or idling is detected, the target speed of the centrifuge can be reduced or the speed increase can be paused; when abnormal speed tracking is detected, the centrifugal driver output can be corrected or a shutdown protection can be triggered.

[0046] After feeding is complete, the linkage controller continues to control the centrifuge to operate in the compaction stage until the preset compaction condition is reached, at which point the centrifuge is controlled to decelerate and stop. The preset compaction condition includes: after the feeding progress reaches 100%, the centrifuge enters a constant-speed compaction stage and maintains operation at 420 rpm for a preset compaction time; when the preset compaction time reaches 3 minutes, the linkage controller controls the centrifuge to smoothly decelerate according to a preset deceleration slope until it stops. By incorporating the constant-speed compaction process after feeding into the preset compaction condition, premature shutdown before the concrete is fully compacted can be avoided, as well as unnecessary energy consumption increases caused by an excessively long compaction stage. In other embodiments, the preset compaction condition can also be determined by combining operating parameters such as the stable state of the centrifuge speed and the changing trend of the centrifuge drive load.

[0047] In this embodiment, the linkage controller also stores the actual feeding curve, actual speed curve, energy consumption data, and corresponding finished product quality data for each production process. The finished product quality data may include inner wall flatness, density, strength test results, or other quality evaluation results. Based on the aforementioned historical data, the linkage controller modifies the target feeding curve, stage speed range, and deviation compensation rules corresponding to the same pipe type, making the control parameters under subsequent identical or similar operating conditions more consistent with actual production conditions, thereby gradually improving control matching and product consistency.

[0048] The following is an example of a working process. Before production begins, the operator selects the corresponding pipe type and process parameters through the human-machine interface unit, and the linkage controller loads the corresponding control parameters. After production starts, the feeder delivers concrete into the rotating pipe mold. The linkage controller determines the current total feeding progress and the filling status of each feeding zone based on the cumulative feeding amount and the material placement position, and determines the current feeding stage accordingly. Subsequently, the linkage controller generates the corresponding target speed of the centrifuge and outputs it to the centrifuge drive. If the feeding progress is detected to be lagging, the centrifuge speed is reduced and the feeding speed is appropriately increased; if the feeding progress is detected to be ahead, the feeding speed is limited and the centrifuge is controlled to enter the next stage according to the rules. After feeding is completed, the linkage controller controls the centrifuge to enter the constant speed compaction stage and continues to run the centrifuge at 420 rpm for 3 minutes to further compact the concrete in the pipe mold; after reaching the preset compaction condition, the linkage controller then controls the centrifuge to smoothly decelerate at a preset deceleration slope until it stops. After production is completed, the linkage controller records the production process data for subsequent parameter correction.

[0049] The following is a specific example of the operation process. Before production begins, the operator selects the DN800×5000 product model through the human-machine interface unit, and the linkage controller loads the corresponding target feeding curve, stage speed range, and deviation compensation rules. After production starts, the feeder and centrifuge start simultaneously, with the initial speed of the centrifuge set to 80 rpm.

[0050] At the 100th second of production, the system detected that the actual feeding progress P was 22% and the target progress P_target(100s) was 23.8%, thus obtaining a progress deviation ΔP of -1.8%. Since this deviation did not exceed the large deviation threshold, the linkage controller only made a small dynamic correction, setting the centrifuge target speed slightly lower than the corresponding reference speed, for example, 132 rpm, to wait for the feeding progress to catch up.

[0051] At the 200th second of production, the system detected an actual feeding progress P of 45%, with ΔP at this point being +0.5%, indicating that the feeding was slightly ahead of schedule. The linkage controller then slightly increased the reference speed based on this progress deviation and set the centrifuge target speed slightly higher than the corresponding reference speed, for example, 222 rpm, to maintain basic synchronization between the compaction and feeding processes.

[0052] At the 350th second of production, the system detected that the actual feeding progress P was 90%, indicating that the final leveling stage had begun, with a target speed of approximately 400 rpm. Under the constraints of the stage speed range and the closed-loop speed regulation, the linkage controller smoothly increased the actual speed of the centrifuge to 400 rpm and maintained it.

[0053] At 420 seconds, the feeding progress reached 100%, and the feeding process ended. The linkage controller then controlled the centrifuge to enter the constant-speed compaction stage, maintaining the centrifuge at 420 rpm for 3 minutes. After reaching the preset compaction condition, the linkage controller then controlled the centrifuge to smoothly decelerate to a stop at a preset slope. The actual feeding progress-time curve, the set speed / actual speed-time curve, and energy consumption data generated throughout the entire production process were recorded and stored for subsequent quality traceability and parameter correction.

[0054] It should be noted that the feeding metering component, position detection component, speed detection component, linkage controller hardware form, number of material distribution zones, deviation compensation method, stage division method, and abnormal working condition identification conditions described in the above embodiments can all be adjusted according to the actual equipment structure and process requirements. As long as they realize the technical idea of ​​linkage control of the feeder and centrifuge based on the real-time feeding status, they should all fall within the protection scope of this invention.

[0055] 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. A PCCP centrifugal molding linkage control system, characterized in that, It includes a feeder unit, a centrifuge unit, a linkage controller, and a human-machine interface unit; The feeding unit includes a conveying mechanism for conveying concrete into the pipe mold, a feeding driver for driving the conveying mechanism, a feeding metering component for detecting the cumulative feeding amount, and a position detection component for detecting the position of the spreading mechanism along the axial direction of the pipe mold. The centrifuge unit includes a tube mold, a centrifugal drive motor for driving the tube mold to rotate, a centrifugal driver connected to the centrifugal drive motor, and a speed detection component for detecting the actual speed of the tube mold. The human-computer interaction unit is used to input pipe type parameters and concrete process parameters; The linkage controller is connected to the feeding driver, the feeding metering component, the position detection component, the centrifugal driver, the speed detection component, and the human-machine interaction unit, respectively, and stores the target feeding curve, stage speed range, stage switching rules, and deviation compensation rules corresponding to different pipe type parameters and concrete process parameters. The linkage controller is used to determine the real-time feeding status based on the cumulative feeding amount and the material placement position, determine the progress deviation and the current material placement stage based on the comparison result between the real-time feeding status and the target feeding curve, generate the centrifuge target speed under the constraints of the stage speed range and stage switching rules, and perform compensation control on at least one of the feeding driver and the centrifuge driver when the progress deviation exceeds the preset range, so as to keep the feeding process synchronized with the centrifugal forming process.

2. The system according to claim 1, characterized in that: The feeding and metering component includes at least one of an encoder mounted on the feeding drive shaft, a level sensor mounted on the hopper or conveying channel, and a weighing sensor. The position detection component includes at least one of a position encoder, a limit switch, and a proximity switch for detecting the axial displacement of the fabric distribution mechanism.

3. The system according to claim 1, characterized in that: The linkage controller is used to divide the inner cavity of the tube mold into multiple material distribution zones along the axial direction based on the detection results of the position detection component, and to obtain the filling status of each material distribution zone by combining the cumulative feeding amount at each time. The linkage controller adjusts the target speed of the centrifuge according to the filling state to limit the speed increase process in the localized material stacking state, and performs stage switching after the partitioned filling state reaches the preset uniformity condition.

4. The system according to claim 1, characterized in that: The linkage controller is also connected to the operating parameter output terminals of the feeding driver and the centrifugal driver to acquire the feeding load signal and the centrifugal load signal, and to perform at least one of the following controls when it detects material blockage, material interruption, idling, slippage or abnormal speed tracking: speed maintenance, speed reduction, speed limiting, shutdown or alarm control.

5. The system according to claim 1, characterized in that: The linkage controller is used to record the actual feeding curve, actual speed curve, energy consumption data and corresponding finished product quality data for each production process, and to correct the target feeding curve, stage speed range or deviation compensation rule corresponding to the same specification tube type based on the recording results.

6. A PCCP centrifugal molding linkage control method based on the system according to any one of claims 1 to 5, characterized in that, Includes the following steps: Input the pipe type parameters and concrete process parameters corresponding to the current production task, and retrieve the corresponding target feeding curve, stage speed range, stage switching rules and deviation compensation rules; Collect the cumulative feeding amount, material distribution position, and actual centrifuge speed to determine the real-time feeding status; The real-time feeding status is compared with the target feeding curve to obtain the progress deviation, and the current material placement stage is determined based on the real-time feeding status. The target speed of the centrifuge is generated under the constraints of the stage speed range and stage switching rules; When the progress deviation is outside the preset range, at least one of the feeder speed, the cloth spreading mechanism running speed and the centrifuge acceleration rhythm shall be corrected in accordance with the deviation compensation rule. Closed-loop speed control is executed based on the target speed and actual speed of the centrifuge. After feeding is completed, maintain centrifugal compaction operation, and control the centrifuge to slow down and stop after reaching the preset compaction conditions, while recording the production process data.

7. The method according to claim 6, characterized in that: The determination of the real-time feeding status includes: determining the total feeding progress based on the cumulative feeding amount, and allocating the total feeding progress to multiple material placement zones divided along the pipe mold axis according to the material placement position, so as to form a zoned filling state that characterizes the distribution of concrete in the pipe mold.

8. The method according to claim 6, characterized in that: When the progress deviation indicates feeding lag, the deviation compensation rule includes at least one of maintaining the current speed of the centrifuge, reducing the centrifuge acceleration slope, increasing the feeder speed, and increasing the operating speed of the fabric spreading mechanism; when the progress deviation indicates feeding ahead, the deviation compensation rule includes at least one of limiting the feeder speed, limiting the operating speed of the fabric spreading mechanism, executing the next stage speed control in advance, and limiting the upper limit of the target speed for the next stage.

9. The method according to claim 6, characterized in that: When generating the target speed of the centrifuge, the target speed is also limited according to the constraints of anti-flying material, anti-segregation and speed-up smoothing, so that the target speed of the centrifuge is always within the allowable speed range corresponding to the current material feeding stage.

10. The method according to claim 6, characterized in that: After production is completed, the actual feeding curve, actual speed curve, energy consumption data and finished product quality data of this production process are linked and stored, and the target feeding curve, stage speed range or deviation compensation rules corresponding to the same specification tube type are corrected accordingly.

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