Electromagnetic vibration feeder based on PID control

Abstract

The utility model provides an electromagnetic vibration feeder based on PID (Proportion Integration Differentiation) control. The electromagnetic vibration feeder comprises a base, a vibration damping column, a vibration bottom plate, an electromagnet seat, a DC24 electromagnet, a vibration plate, a material distribution groove, a sensor and an armature, accurate feeding of materials is achieved through electromagnetic vibration. The DC24V electromagnetic vibration system can form a plurality of closed-loop control systems. The closed-loop control scheme comprises power closed-loop control, amplitude control and material flow speed control. Each closed-loop system involves dedicated sensor feedback, control algorithms, and drive actuators. The system provided by the utility model can adapt to different working environments and conditions, such as temperature change, power supply fluctuation and the like, so that the stability of equipment is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of particle size testing instruments, in particular to an electromagnetic vibration feeder based on PID control. Background Art

[0002] Most of the existing electromagnetic vibration feeders currently in use adopt open-loop control, with a power supply voltage of AC220V, which cannot meet the need of the whole machine instrument with a power supply of DC24V. It only relies on the feedback signal of the acceleration sensor to adjust the vibration frequency or amplitude. This AC220V electromagnetic vibrator solution is mainly suitable for generating vibration to achieve material transportation, separation or stirring in various applications, and is used in the dispersion and picking of large workpieces. In applications requiring high precision such as particle size testing, it shows obvious limitations. For example: (1) Insufficient voltage range. The voltage is supplied by AC220V, which is suitable for large equipment and cannot meet the need of the safe voltage DC24V for precision instruments. (2) Large electromagnetic interference (EMI). The electromagnetic vibration feeder powered by AC220V generates too much electromagnetic interference, causing serious electromagnetic interference to surrounding electronic devices, resulting in the internal main control chip resetting from time to time, seriously affecting production efficiency. (3) Insufficient control precision. Most of the existing technologies only adopt open-loop control and do not form a closed-loop control. Some with closed-loop can only feedback the vibration speed of the material in the vibration system to form a single speed closed-loop control; the vibration amplitude intensity can only be adjusted by a manual potentiometer and cannot form a closed-loop automatic control according to the actual material movement speed. This leads to differences in the characteristics of different materials during testing, and it is impossible to automatically adjust the closed-loop accurately to match the actual requirements during the testing process, affecting the accuracy of the test results. (4) Poor consistency. Unstable AC220V voltage on site, different mechanical structure installation stresses, inconsistent elastic forces of damping columns and spring sheets, different gaps between the armature and the electromagnet, and too large power error of the electromagnet may cause inconsistent responses to the same vibration signal. (5) Poor stability. When the material flow changes, the system is difficult to respond in a timely manner, and the adjustment of the vibrator lags behind. Especially when dealing with fine particles, the feeding speed is prone to fluctuations and it is difficult to maintain stability. (6) Poor dynamic performance. When the frequency and load of the existing single closed-loop system change greatly, it is easy to oscillate, which in turn affects the continuity of material supply. In severe cases, it may cause equipment damage or feeding interruption. There is only a single closed-loop control by relying on the feedback of the material speed value of the vibration, and it is impossible to form a multi-closed-loop control.

[0003] The system design and implementation of the current existing technology are relatively simple and suitable for scenarios with low performance requirements. Summary of the Utility Model

[0004] The purpose of the utility model is to provide an electromagnetic vibration feeder based on PID control to solve the problems raised in the above background art.

[0005] For the above purposes, the present utility model provides the following technical solutions:

[0006] An electromagnetic vibration feeder based on PID control, comprising a base, damping columns, a vibration base plate, an electromagnet seat, a DC24 electromagnet, a vibration plate, a feeding trough, a sensor and an armature;

[0007] The damping columns are arranged at the four corners of the base, and the vibration base plate is fixed on the damping columns by screws;

[0008] The electromagnet seat, the DC24 electromagnet and the armature are all fixed on the vibration base plate by screws;

[0009] Both the front and rear ends of the vibration base plate are provided with inclined and symmetric spring pieces;

[0010] The top end of the vibration base plate is provided with a vibration plate and a sensor, and the sensor is arranged between the two vibration plates;

[0011] The feeding trough is fixed on the two vibration plates by screws;

[0012] A three-closed-loop system of the electromagnetic vibration feeder is composed of a DC24V electromagnetic vibration feeder, a camera and a control board;

[0013] An industrial camera is used to take continuous images of the particle flow, and an image processing algorithm will detect and mark the positions of the particles in each frame of the image;

[0014] The control board performs PID algorithm control according to the collected voltage, current, amplitude, displacement and speed;

[0015] Through the vibration of the DC24V electromagnet, a multi-layer feedback control strategy for its power, amplitude and speed is adopted to achieve the stability of the falling speed of the material flow particles. Vibration is used to disperse and spread the material flow particles evenly to meet the requirements of the industrial camera for taking particle images.

[0016] The material flow particles can be detected by edge detection, threshold segmentation, or object detection using deep learning.

[0017] After the industrial camera obtains the displacement information of the material flow particles in different image frames through machine vision algorithms, the speed of the material flow particles can be calculated through the following formula;

[0018] Material flow speed: v = △x / △t

[0019] Wherein, v is the speed of the material flow particles, △x is the displacement of the material flow particles in adjacent frames, and △t is the time interval between the camera taking two frames of images.

[0020] The PID algorithm is implemented by a control board. The PID controller can adjust the amplitude, frequency, speed, and acceleration of electromagnetic vibration to keep the system vibrating stably under specific conditions;

[0021] The control board is powered by a safe low voltage of DC24V and has multiple interfaces for connecting to external devices;

[0022] The control board collects the current and working voltage in the DC24V electromagnet to complete power closed-loop feedback for the outermost loop control; according to needs, the control board collects the vibration speed, acceleration, displacement angle, and frequency of the material flow particles through sensors to form a closed-loop control for the secondary inner loop a; the industrial camera calculates the material flow speed and feeds it back to the control board in real time to form a closed-loop control for the inner loop b;

[0023] Among them, the outermost loop is the first loop, the inner loop a is the second loop, and the inner loop b is the third loop;

[0024] Through the precise control of the three closed loops formed by the outermost loop, inner loop a, and inner loop b, the system can adjust and optimize the working state of the electromagnetic coil in real time, making the vibration frequency and amplitude stable within the optimal range.

[0025] The DC24V electromagnet selects alloy magnetic materials, optimizes the number of turns of the coil to increase magnetic flux, and uses a half-bridge push-pull drive for the electromagnet, which can work at a maximum frequency of 1KHz.

[0026] The sensor adopts a multi-functional parameter sensor, which can collect the vibration speed, acceleration, displacement angle, and frequency of the material flow particles according to needs, and combines with advanced high-speed circuit design to achieve optimal control of the high-precision, stability, and dynamic response performance of the material supply process.

[0027] The sensor can be replaced with a six-axis attitude sensor or a nine-axis motion sensor device.

[0028] On the basis of PID control, adaptive and image vision control algorithms can also be introduced.

[0029] In addition to power feedback, a feedback mechanism such as current feedback can also be used to adjust the vibration parameters of the electromagnetic vibration system.

[0030] Beneficial effects

[0031] The utility model significantly improves the performance of the electromagnetic vibration feeder through a three-closed-loop PID control system. The specific advantages are as follows: (1) High-precision feeding: An electromagnet powered by DC24V is adopted, and the working voltage and current of the electromagnet are collected to calculate the power. The control board can accurately control the suction force of the electromagnet by controlling the magnitude of the current through the PID algorithm, thereby realizing fine control. The three-closed-loop control enables the system to accurately adjust parameters such as the flow rate of material particles, vibration amplitude, and power, adapting to changes in the characteristics of different material particles. (2) Safe and reliable: The DC24V DC voltage belongs to the low-voltage range. Compared with higher-voltage systems, it poses a lower safety risk to the human body. The DC24V DC power supply and related control components usually have lower costs. Compared with high-voltage systems, the DC24V DC system generates less electromagnetic interference, which helps to improve the anti-interference ability of the system. The low-voltage system generates less heat, which helps to reduce component wear and extend the service life of the electromagnet. (3) Fast response: DC24V belongs to a relatively low voltage level, which means that the internal resistance of the power supply system is small, and current changes can be transmitted to the electromagnet faster. The integrated sensor feedback system (such as displacement) can monitor the state of the electromagnet and quickly adjust the current when needed to achieve precise and fast control, thereby realizing fast response and real-time feedback to ensure that the system can quickly adjust vibration parameters and avoid feeding fluctuations caused by load changes. (4) Reducing the risk of oscillation: Feedback control helps to reduce the influence of system errors and external disturbances and improve the stability of the system. The three-closed-loop feedback mechanism effectively suppresses the oscillation phenomenon during high-frequency vibration or large load changes. The system can adapt to different working environments and conditions, such as temperature changes and power fluctuations, improving the stability of the equipment.

[0032] The utility model solves the problems of strong electromagnetic interference, insufficient control accuracy, poor consistency, poor stability, and poor dynamic performance caused by the AC220V power supply system. This system not only effectively reduces electromagnetic interference but also significantly improves the response speed and control accuracy of the feeder, ensuring high consistency and stability under complex working conditions and meeting the requirements for high-precision material supply in industrial automation production. Brief Description of the Drawings

[0033] Figure 1 It is the front view of the electromagnetic vibration feeder;

[0034] Figure 2 It is the top view of the electromagnetic vibration feeder;

[0035] Figure 3 It is the left view of the electromagnetic vibration feeder;

[0036] Figure 4 It is the three-dimensional structure diagram a of the electromagnetic vibration feeder;

[0037] Figure 5It is the three-dimensional structure diagram b of the electromagnetic vibration feeder;

[0038] Figure 6 It is the block diagram of the three-closed-loop system of the electromagnetic vibration feeder;

[0039] Figure 7 It is the circuit block diagram of the control module.

[0040] Among them, 1. Base, 2. Vibration damping column, 3. Vibration bottom plate, 4. Electromagnet seat, 5. DC24 electromagnet, 6. Vibration plate, 7. Feeding trough, 8. Sensor, 9. Armature, 10. Spring piece, 11. Screw, 12. Industrial camera, 13. Material flow particles. Specific implementation mode

[0041] The following will clearly and completely describe the present utility model in conjunction with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present utility model without creative work shall fall within the protection scope of the present utility model.

[0042] Please refer to the attached Figure 1-7 , an electromagnetic vibration feeder based on PID control, including a base 1, vibration damping columns 2, a vibration bottom plate 3, an electromagnet seat 4, a DC24 electromagnet 5, a vibration plate 6, a feeding trough 7, a sensor 8 and an armature 9;

[0043] The vibration damping columns 2 are arranged at the four corners of the base 1, and the vibration bottom plate 3 is fixed on the vibration damping columns 2 by screws;

[0044] The electromagnet seat 4, DC24 electromagnet 5 and armature 9 are all fixed on the vibration bottom plate 3 by screws 11;

[0045] The front and rear ends of the vibration bottom plate 3 are both provided with inclined and symmetric spring pieces 10;

[0046] The top of the vibration bottom plate 3 is provided with a vibration plate 6 and a sensor 8, and the sensor 8 is arranged between the two vibration plates 6;

[0047] The feeding trough 7 is fixed on the two vibration plates 6 by screws;

[0048] The DC24V electromagnetic vibration feeder, industrial camera 12 and control board form a three-loop of the electromagnetic vibration feeder;

[0049] The industrial camera 12 is used to take continuous images of the flow of the material flow particles, and the image processing algorithm will detect and mark the positions of the material flow particles in each frame of the image;

[0050] The control board performs PID algorithm control according to the collected voltage, current, amplitude, displacement and speed;

[0051] Through the vibration of the DC 24V electromagnet 5, a multi-layer feedback control strategy for its power, amplitude, and speed is adopted to achieve the stability of the falling speed of the material flow particles. Vibration is used to disperse and spread the material flow particles evenly to meet the requirements for the industrial camera 12 to capture particle images.

[0052] The material flow particles 13 can be detected through edge detection, threshold segmentation, or object detection using deep learning.

[0053] After the industrial camera 12 obtains the displacement information of the material flow particles in different image frames through machine vision algorithms, the speed of the material flow particles can be calculated through the following formula;

[0054] Material flow speed: v = △x / △t

[0055] Where, v is the speed of the material flow particles, △x is the displacement of the material flow particles in adjacent frames, and △t is the time interval between the camera taking two frames of images.

[0056] The PID algorithm is implemented by the control board. The PID controller can adjust the amplitude, frequency, speed, and acceleration of the electromagnetic vibration to keep the system vibrating stably under specific conditions;

[0057] The control board is powered by a safe low voltage DC 24V and has multiple interfaces to connect to external devices;

[0058] The control board collects the current and working voltage in the DC 24V electromagnet to complete the power closed-loop feedback and achieve the outermost loop control; according to needs, the control board collects the vibration speed, acceleration, displacement angle, and frequency of the material flow particles through sensors to form the closed-loop control of the secondary inner loop a; the camera calculates the material flow speed and feeds it back to the control board in real time to form the closed-loop control of the inner loop b;

[0059] Among them, the outermost loop is the first loop, the inner loop a is the second loop, and the inner loop b is the third loop.

[0060] Through the precise control of the three closed loops formed by the outermost loop, inner loop a, and inner loop b, the system can adjust and optimize the working state of the electromagnetic coil in real time, so that the vibration frequency and amplitude are stabilized within the optimal range.

[0061] The DC 24V electromagnet 5 is made of alloy magnetic material, the number of turns of the coil is optimized to increase the magnetic flux, and the half-bridge push-pull drive is used for this electromagnet, which can work at a maximum frequency of 1KHz.

[0062] The sensor 8 adopts a multi-functional parameter sensor, which can collect the vibration speed, acceleration, displacement angle, and frequency of the material flow particles according to needs. Combining with advanced high-speed circuit design, it realizes the optimal control of the high precision, stability, and dynamic response performance of the material supply process.

[0063] The sensor 8 can be replaced with a six-axis attitude sensor or a nine-axis motion sensor device.

[0064] Based on PID control, adaptive and image vision control algorithms can also be introduced.

[0065] In addition to power feedback, a feedback mechanism such as current feedback can also be used to adjust the vibration parameters of the electromagnetic vibration system.

[0066] An electromagnetic vibration feeder composed of a base 1, damping columns 2, a vibrating bottom plate 3, an electromagnet base 4, an electromagnet 5, a vibrating plate 6, a feeding trough 7, a sensor 8, an armature 9, a spring plate 10, and screws 11 realizes the precise supply of cooking particles through electromagnetic vibration.

[0067] The DC24V electromagnetic vibration system can form multiple closed-loop control systems. The closed-loop control scheme includes power closed-loop control, amplitude (displacement) control, and material flow speed control. Each closed-loop system involves dedicated sensor feedback, control algorithms, and drive actuators.

[0068] The control board performs PID algorithm control based on the collected voltage, current, amplitude, displacement, and speed, which can effectively handle the feedback control problem of the system and improve the stability and dynamic response of the system. Specifically, the PID controller can adjust the amplitude, frequency, speed, and acceleration of the electromagnetic vibration, so that the system maintains stable vibration under specific conditions.

[0069] The following are embodiments of the closed-loop control scheme;

[0070] Embodiment 1

[0071] Power closed-loop control

[0072] Objective: The control board collects the voltage and current of the electromagnet and calculates the power in real time to form the outermost loop control in the first closed loop.

[0073] Process of forming the closed loop: The power cord led out from the electromagnet 5 is connected to the control board. The control board collects the working voltage and current of the electromagnet to calculate the power and forms the first closed loop. The control board calculates the error (the difference between the desired position and the actual position) through algorithms such as PID according to the collected electrical signals of the electromagnet 5. The controller adjusts the duty cycle of the PWM to drive the MOS tube in the control board to control the voltage and frequency of the electromagnet, thereby changing the electromagnet current. The change in current and frequency causes a change in the magnetic field of the electromagnet 5, resulting in a change in the suction force with the armature 9, and adjusting the displacement and frequency of the vibrating plate 6 to reach the target position. The feedback continues until the position of the vibrating plate 6 remains stable at the set value.

[0074] Embodiment 2

[0075] Amplitude (displacement) closed-loop control

[0076] Objective: According to the signal collected by sensor 8, the control board outputs a signal to control electromagnet 5 and electromagnet base 4. The electromagnet controls the displacement of the vibrating plate through current, ensuring that the vibration meets the process requirements.

[0077] Composition: Sensor 8 monitors the vibration amplitude (displacement) of the vibrating plate in real time. Electromagnet 5 and electromagnet base 4 adjust the vibration amplitude by receiving voltage changes, thereby controlling the displacement of the material flow particles in the cloth chute 7. The spring plate 10 is an elastic structure that provides damping and reset force. The vibrating bottom plate 3 and the damping columns reduce excessive vibration through physical structures. The vibrating plate 6, spring plate 10, and armature 9 form the core mechanism of vibration. The vibrating plate realizes periodic vibration through the reaction force of the spring plate.

[0078] Closed-loop process: Sensor 8 measures the vibration amplitude of the vibrating plate. The control board compares the target amplitude and calculates the error. The control board adjusts the driving voltage of the electromagnet to change the electromagnet current and regulate the vibration amplitude. The adjustment result is fed back to the sensor to form a closed-loop control.

[0079] Embodiment 3

[0080] Material flow velocity closed-loop control

[0081] Objective: Analyze the pictures taken by the camera within a fixed time, determine the velocity by analyzing the displacement of the material flow particles in two frames of images, and control the flow rate of the material flow particles in the cloth chute to ensure uniform feeding.

[0082] Composition: Camera 12 provides visual feedback to help accurately control the flow of material flow particles. Electromagnet 5 and vibrating plate 6 adjust the vibration frequency and amplitude, affecting the flow rate of the material. The cloth chute 7 carries the material flow particles and moves the material flow particles through vibration.

[0083] Closed-loop process: Camera 12 and sensor 8 monitor the flow velocity and vibration velocity of the material flow particles in the cloth chute. The control board calculates based on the material flow monitored by the camera and then inputs the feedback signal into the control board. The main control chip of the control board outputs PWM to change the duty cycle and frequency to drive the power MOS tube to drive the electromagnet to work, so as to adjust the intensity and frequency of vibration. By adjusting the electromagnet current, the vibration amplitude and frequency are controlled to adjust the material flow particles 13. By adjusting the vibration of the vibrating plate, the flow rate of the material flow particles is controlled. The feedback continues to ensure that the material flow is within the set range.

[0084] Power closed-loop control adjusts the electromagnet current to achieve position control by feedback of the working voltage and current signals of the electromagnet coil.

[0085] Vibration closed-loop control adjusts the current of the electromagnet to control the vibration state through feedback of the vibration frequency and amplitude.

[0086] The closed-loop control of the material flow adjusts the vibration parameters to control the flow of material particles by monitoring the condition of the material particles in the cloth chute. These closed-loop control systems work together to achieve the efficient operation of the electromagnetic vibration system.

[0087] The system adopts the PID control algorithm to adjust the vibration frequency and amplitude of the electromagnet through the circuit to ensure the accuracy of the material supply. This control system realizes closed-loop regulation through three-way feedback signals fed back to the control board.

[0088] The three-loop PID control is to connect three PID control systems (for example: power loop, amplitude (displacement) loop, and speed loop) in series, and then calculate the deviation of the output of the previous system (outer loop), and the calculation result is used as the input of the next system (inner loop). The material flow speed captured by the camera is the object of priority control. The process of the three-loop PID control is as follows:

[0089] ① First, set the power intensity. The system will calculate the power intensity deviation and then input the deviation into the power loop (the outermost loop);

[0090] ② Calculate the deviation between the output of the power loop and the displacement output by the actual sensor, and input the calculated deviation into the amplitude (displacement) loop (the second outermost loop);

[0091] ③ Comprehensively calculate the deviation between the output of the amplitude (displacement) loop and the material flow speed deviation output by the camera, and input the calculated deviation into the current loop (the inner loop). The output of the current loop is used to control the duty cycle and frequency of the PWM of the MOS tube in the control board, and then finally control the material flow speed. Make the material flow particles stable, the measured particle size and particle shape results accurate, and the consistency between instruments small.

[0092] Although the present utility model has been described in detail with reference to the foregoing embodiments, for those skilled in the art, they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. An electromagnetic vibration feeder based on PID control, characterized in that, It includes a base, shock-absorbing columns, a vibrating bottom plate, an electromagnet seat, a DC24 electromagnet, a vibrating plate, a feeding trough, a sensor and an armature; The shock-absorbing columns are arranged at the four corners of the base, and the vibrating bottom plate is fixed on the shock-absorbing columns by screws; The electromagnet seat, the DC24 electromagnet and the armature are all fixed on the vibrating bottom plate by screws; Symmetrically inclined spring plates are arranged at both the front and rear ends of the vibrating bottom plate; A vibrating plate and a sensor are arranged at the top of the vibrating bottom plate, and the sensor is arranged between the two vibrating plates; The feeding trough is fixed on the two vibrating plates by screws; A three-closed-loop system of the electromagnetic vibrating feeder is composed of a DC24V electromagnetic vibrating feeder, a camera and a control board; An industrial camera is used to take continuous images of the flow of material particles, and an image processing algorithm will detect and mark the positions of the particles in each frame of the image; The control board performs PID algorithm control according to the collected voltage, current, amplitude, displacement and speed; Through the vibration of the DC24V electromagnet, a multi-layer feedback control strategy of its power, amplitude and speed is adopted to achieve the stability of the falling speed of the material flow particles. Vibration is used to disperse and spread the material flow particles evenly to meet the requirements of the industrial camera for taking particle images.

2. The electromagnetic vibration feeder based on PID control according to claim 1, characterized in that, The material flow particles are detected by edge detection, threshold segmentation, or object detection using deep learning.

3. The electromagnetic vibration feeder based on PID control according to claim 1, characterized in that, The DC24V electromagnet selects an alloy magnetic material, optimizes the number of turns of the coil to increase the magnetic flux, and uses a half-bridge push-pull drive for the electromagnet, which can work at a maximum frequency of 1KHz.

4. The electromagnetic vibration feeder based on PID control according to claim 1, characterized in that, The sensor uses a multi-functional parameter sensor.

5. An electromagnetic vibration feeder based on PID control according to claim 1, characterized in that, The sensor can be replaced by a six-axis attitude sensor or a nine-axis motion sensor device.

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