A filling control system capable of synchronous lifting and horizontal propulsion

Abstract

A loading control system capable of synchronous lifting and horizontal propulsion, relating to the field of automatic control technology, is disclosed. It includes a remote upper-level platform; an electrical cabinet comprising a control interaction unit, controller, communication unit, and alarm module; a lifting platform including a lifting cylinder, proportional servo valve, hydraulic station, and displacement sensor; and a thrust platform including a drive device, encoder, tension / compression sensor, intelligent instrument, thrust component, and chain. The controller of this invention outputs analog signals through a PID position closed-loop to control the opening of the proportional servo valve, thereby controlling the speed and position of the lifting cylinder. Simultaneously, it optimizes the algorithm based on errors during the synchronization process. When the feedback position is far from the target, a following algorithm is adopted, and real-time corrections are made based on the synchronization error to ensure synchronization accuracy during movement. Horizontal propulsion employs a vector control method with encoder closed-loop, achieving low-frequency, high-torque output and multi-speed propulsion control modes, allowing for flexible adjustment of the propulsion state according to requirements.

Description

Technical Field

[0001] This utility model relates to the field of automatic product loading control technology, specifically a loading control system that can realize synchronous lifting and horizontal propulsion. Background Technology

[0002] With the continuous advancement of technology, automation and intelligence of equipment are the current development trend. Currently, most filling operations on product manufacturing production lines are still manually operated, which has the following drawbacks: 1. Loading operators need to stand on the assembly line for long periods of time, and the operation process is complicated, which not only increases the difficulty of operation, but also takes a long time and seriously affects production efficiency.

[0003] 2. Due to the long hours and repetitive work of the operators, it is difficult to guarantee the filling quality.

[0004] 3. Manual loading is complex to operate, requires a lot of trial and error and adjustment, and lacks systematic data support, making it difficult to optimize parameters scientifically.

[0005] 4. The filling operations performed by different personnel may vary significantly, resulting in poor consistency in filling quality.

[0006] 5. When faced with complex products or changing requirements, manual loading methods are difficult to adjust and struggle to adapt to rapidly changing production needs, lacking flexibility. Summary of the Invention

[0007] To overcome the shortcomings of the existing technology, the purpose of this invention is to provide a loading control system that can realize synchronous lifting and horizontal propulsion, so as to improve the automation and intelligence level of loading operations, realize multi-task parallelism, and improve loading operation efficiency.

[0008] To achieve the above-mentioned objectives, the present invention provides a loading control system capable of synchronous lifting and horizontal propulsion, comprising a remote upper-level platform; an electrical cabinet comprising a control interaction unit, a controller, a communication unit, and an alarm module; a lifting platform for adjusting the lifting motion of the equipment comprising a lifting cylinder, a proportional servo valve, a hydraulic station, and a displacement sensor; and a thrust platform for adjusting the horizontal pushing and pulling motion of the equipment comprising a drive device for controlling the motion state of the thrust components, an encoder, a tension / compression sensor, an intelligent instrument, thrust components, and a chain. The controller is installed in the electrical cabinet and is used for data calculation and logic control of the equipment. The controller receives parameters sent by the tension and compression sensors and displacement sensors, processes the signals for input and output, and performs calculation and control based on real-time parameters to automatically execute the lifting and lowering of the jacking platform and the horizontal propulsion of the thrust platform. The communication unit is installed in the electrical cabinet and is connected to the controller and the smart meter via a bus. The communication unit sends the data information collected by the smart meter to the controller.

[0009] Furthermore, the lifting platform is slidably connected to the guide rail of the equipment base via a slider; a displacement sensor for detecting the position of the lifting cylinder is installed on the lifting cylinder, and the displacement sensor is electrically connected to the controller; two lifting cylinders are symmetrically installed below the loading support, and the piston rod of the lifting cylinder is connected and fixed to the bottom of the loading support, which has an arc-shaped structure to match the shape of the loading material; the hydraulic station provides a power source for the lifting cylinder; a proportional servo valve for adjusting the speed and position of the lifting cylinder is installed on the hydraulic station and is connected to the controller and the lifting cylinder respectively.

[0010] Furthermore, the slider two at the bottom of the thrust platform is slidably connected to the guide rail of the equipment base, and the bottom two sides of the thrust trolley are connected to the chain by pins. The two ends of the tension and compression sensor used to detect the tension value during the pushing process of the equipment are respectively connected to the chain and the thrust trolley. The tension and compression sensor is electrically connected to the intelligent instrument. One end of the coupling is fixed on the thrust trolley, and the other end is connected to the loading material. The coupling is a non-telescopic universal joint coupling that can adapt to positional deviation. The drive unit is mounted on the equipment base. The motor is connected to one end of the coupling via a gear reducer. The other end of the coupling is connected to the drive sprocket by a key. The connecting shaft between the drive sprocket and the driven sprocket is connected to the equipment base by a bearing. The chain meshes with the drive sprocket and the driven sprocket. The motor drives the chain to drive the thrust component. An encoder for closed-loop control of the speed vector of the drive unit is connected to the drive unit. An intelligent instrument is mounted on the thrust platform to display the collected tension values ​​from the tension and compression sensors and communicates with the communication unit via serial port.

[0011] Furthermore, the control interaction unit is installed inside the electrical cabinet and is connected to the electrical cabinet via a bus for the operation, alarm, display, and data recording of the equipment.

[0012] Furthermore, the remote host platform is set as an industrial control computer, a laptop, or a desktop computer, and sends the loading and running status and information to the cloud.

[0013] Furthermore, the alarm module is installed inside the electrical cabinet and electrically connected to the controller, and is used for audible and visual alarms when the equipment is depressurized, has synchronization errors, or is subjected to excessive tension. The pressure relief alarm is triggered when the lifting platform experiences pressure relief, causing the lifting cylinder to descend to a threshold value. The synchronization error alarm is triggered when the positional error between multiple lifting cylinders reaches a first threshold during synchronous lifting movements, and when it exceeds a second threshold, the equipment is shut down for protection. The first threshold is less than the second threshold. The tension alarm stops the drive device output when the tension value reaches a set threshold during the forward and backward movement of the thrust component, thus preventing damage to the equipment.

[0014] Compared with the prior art, this utility model has the advantages of low labor input cost, more flexible and convenient operation, and safety and reliability: 1. The controller outputs analog signals through a PID position closed-loop control to control the opening of the proportional servo valve, thereby controlling the speed and position of the lifting cylinders. Simultaneously, based on the synchronization error, the algorithm is optimized. When the feedback position is far from the target, a following algorithm is used, setting the first lifting cylinder as the primary reference axis and the other lifting cylinders as secondary axes, following the movement of the first lifting cylinder. Real-time corrections are made based on the synchronization error to ensure synchronization accuracy during movement. When approaching the target, each lifting cylinder uses independent positioning control to ensure target position accuracy, achieving precise and rapid synchronized lifting movements of multiple sets of lifting cylinders, simplifying the operation process and saving time.

[0015] 2. The horizontal propulsion adopts a vector control method with encoder closed loop to achieve low-frequency high torque output and multi-speed propulsion control mode. The propulsion state can be flexibly adjusted according to the needs, and the thrust is monitored in real time through tension and compression sensors to limit the drive output and ensure equipment safety.

[0016] 3. It is also equipped with an emergency stop brake to protect users from injury and make it convenient for users to use. Attached Figure Description

[0017] To make the content of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein: Figure 1 This is a block diagram of the electrical system structure of this utility model.

[0018] Figure 2 This is a schematic diagram of the structure of this utility model.

[0019] Figure 3 for Figure 2 A simplified structural diagram of the central lifting platform.

[0020] Figure 4 for Figure 2 A simplified structural diagram of a medium-thrust platform.

[0021] Figure 5 for Figure 4A simplified schematic diagram of the drive unit.

[0022] Explanation of reference numerals: 100, Electrical cabinet; 110, Control and interaction unit; 120, Controller; 130, Communication unit; 140, Alarm module; 200, Lifting platform; 210, Lifting cylinder; 220, Proportional servo valve; 230, Hydraulic station; 240, Displacement sensor; 250, Slider 1; 260, Loading support; 300, Thrust platform; 310, Drive device; 310-1, Motor; 310-2, Gear reducer; 310-3, Drive sprocket; 320, Encoder; 330, Tension / compression sensor; 340, Intelligent instrument; 350, Thrust component; 360, Chain; 370, Slider 2; 380, Thrust trolley; 390, Coupling; 400, Remote upper platform; 500, Equipment base. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] If the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0025] like Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5As shown, the present invention provides a loading control system capable of synchronous lifting and horizontal propulsion, comprising a remote upper platform 400; an electrical cabinet 100 mounted on a drive unit 310, comprising a control interaction unit 110, a controller 120, a communication unit 130, and an alarm module 140; a lifting platform 200, comprising a lifting cylinder 210, a proportional servo valve 220, a hydraulic station 230, and a displacement sensor 240; and a thrust platform 300, comprising a drive unit 310, an encoder 320, a tension / compression sensor 330, an intelligent instrument 340, a thrust component 350, and a chain 360.

[0026] The controller 120 is installed inside the electrical cabinet 100 and is used for data calculation and logic control of equipment actions. The controller 120 receives parameters sent by the tension / compression sensor 330 and the displacement sensor 240, processes the signals for input and output, and performs calculations and control based on real-time parameters to automatically execute the lifting and lowering operations of the lifting platform 200 and the horizontal propulsion operations of the thrust platform 300. The electrical cabinet 100 includes the up and down buttons for the three sets of lifting cylinders 210 of the lifting platform 200, the overall up and down buttons for the three sets of lifting cylinders 200, and the forward, backward, start, and emergency stop buttons for the thrust platform 300.

[0027] The communication unit 130 is installed inside the electrical cabinet 100 and is connected to the controller 120 and the smart meter 340 via a bus. The communication unit 130 sends the data information collected by the smart meter 340 to the controller 120.

[0028] The control interaction unit 110 is installed inside the electrical cabinet 100. The control interaction unit 110 is connected to the electrical cabinet 100 via a bus and is used for the operation, alarm, display and data recording of the equipment.

[0029] The remote host platform 400 can be set as an industrial control computer, laptop, or desktop computer to send loading and running status and information to the cloud.

[0030] The alarm module 140 is installed inside the electrical cabinet 100 and electrically connected to the controller 120. It is used for audible and visual alarms when the equipment experiences pressure relief, synchronization error, or excessive tension. The pressure relief alarm is triggered when the lifting platform 200 experiences pressure relief, causing the lifting cylinder 210 to descend to a threshold value. The synchronization error alarm is triggered when the positional error between multiple lifting cylinders 210 reaches a first threshold value during synchronous lifting movements. If the error exceeds a second threshold value, the equipment is shut down for protection. The first threshold value is less than the second threshold value. The tension alarm is triggered when the tension value detected during the forward and backward movement of the thrust component 350 reaches a set threshold value, stopping the output of the drive device 310 to prevent damage to the equipment.

[0031] Among them, the controller 120 is a Siemens programmable controller; the communication unit 130 is a Siemens communication unit; the proportional servo valve 220 is model 4WRPEH6C3B04L-2X / G24K0 / F1M; the hydraulic station 230 is manufactured by Changzhou Dex; the tension / compression sensor 330 is model DYLY-101; and the displacement sensor 240 is model LMR146 (measuring length is 90mm).

[0032] The lifting platform 200 is used to adjust the lifting motion of the equipment. The lifting platform 200 is slidably connected to the guide rail of the equipment base 500 via a slider 250; the displacement sensor 240 is installed on the lifting cylinder 210 to detect the position of the lifting cylinder 210, and the displacement sensor 240 is electrically connected to the controller 120; two lifting cylinders 210 are symmetrically installed below the filling support 260, and the piston rod of the lifting cylinder 210 is connected and fixed to the bottom of the filling support 260, which has an arc-shaped structure to match the shape of the filling material; the hydraulic station 230 provides a power source for the lifting cylinders 210; the proportional servo valve 220 is installed on the hydraulic station 230 to adjust the speed and position of the lifting cylinders 210, and the proportional servo valve 220 is connected to both the controller 120 and the lifting cylinders 210.

[0033] Specifically, the displacement sensor 240 is connected to the controller 120, and the position information of the lifting cylinder 210 is obtained after amplification and A / D conversion. When the lifting cylinder 210 performs synchronous lifting operation, after selecting the lifting mode and setting the target position through the control interaction unit 110, the controller 120 compares the target position with the feedback position of the displacement sensor 240. The controller 120 outputs an analog signal to the proportional servo valve 220 through PID position closed loop, controls the opening of the proportional servo valve 220, thereby controlling the speed of the lifting cylinder 210, and finally realizing position control.

[0034] Furthermore, when the lifting cylinder 210 generates a synchronization error during synchronous lifting, algorithm optimization is required to control the synchronization error within a first threshold range. When the feedback position is far from the target, a following algorithm is adopted, setting the first lifting cylinder 210 as the main reference axis and the other five lifting cylinders 210 as secondary axes, following the movement of the first lifting cylinder 210 and correcting it in real time according to the synchronization error to ensure synchronization accuracy during the movement. When approaching the set target position, each lifting cylinder 210 independently uses positioning control to ensure the target position accuracy.

[0035] The first threshold and the second threshold are preset values ​​used to determine whether the synchronization error is too large. For example, the first threshold can be 1 mm and the second threshold can be 2 mm.

[0036] The thrust platform 300 is used to adjust the horizontal pushing and pulling action of the equipment. The slider 370 at the bottom of the thrust platform 300 is slidably connected to the guide rail of the equipment base 500. The bottom sides of the thrust trolley 380 are connected to the chain 360 by pins. The tension / compression sensor 330, used to detect the tension value during the equipment's movement, is connected at both ends to the chain 360 and the thrust trolley 380 respectively, and is electrically connected to the intelligent instrument 340. One end of the coupling 390 is fixed to the thrust trolley 380, and the other end is connected to the loading material. The coupling 390 is a non-telescopic universal joint that can adapt to positional deviations. The drive device 310 is used to control the movement state of the thrust component 350. The drive device 310 is mounted on the equipment base 500, and the motor 310-1 is driven by a gear reducer 3. 10-2 is connected to one end of the coupling, and the other end of the coupling is connected to the drive sprocket 310-3 by a key. The connecting shaft between the drive sprocket 310-3 and the driven sprocket is connected to the equipment base 500 by a bearing. The chain 360 meshes with the drive sprocket and the driven sprocket. The motor drives the chain 360 to drive the thrust component 350 to run. The encoder 320 is connected to the drive device 310 and is used to perform closed-loop control of the speed vector of the drive device 310. The encoder 320 can achieve high torque output at low frequency, bear a larger load, and at the same time ensure speed accuracy. The intelligent instrument 340 is installed on the thrust platform 300, displays the collected tension value of the tension sensor 330, and communicates with the communication unit 130 via serial port.

[0037] Specifically, when the thrust component 350 moves horizontally, the tension sensor 330 detects the tension data in real time during the pushing process. The tension data is collected and displayed by the intelligent instrument 340. The intelligent instrument 340 transmits the data to the communication unit 130 via serial communication. The communication unit 130 sends the data to the controller 120 via the bus. When the controller 120 detects that the tension is greater than the set threshold, it limits the output of the drive device 310 and alarms and stops the machine.

[0038] The threshold value is a pre-set value used to determine whether the monitored tensile force is too high. For example, the threshold value can be 2000N, 3000N, etc.

[0039] The controller 120 is further used for motion control of the thrust platform 300.

[0040] Specifically, the control interaction unit 110 is a Siemens touchscreen used for operation, alarm, display, and data recording. The control interaction unit 110 is connected to the controller 120 via a bus. During horizontal movement, the control interaction unit 110 selects the control mode and movement speed, and sends control commands to the controller 120. The control modes are divided into jog mode and continuous mode, and the movement speeds are divided into low speed, high speed, and jog speed. The controller 120 sends commands to the drive device 310 according to the control commands, and the drive device 310 drives the chain 360 to move the thrust component 350 back and forth.

[0041] It should be noted that the jog mode refers to the thrust component 350 advancing or retracting 2mm in a single operation after receiving the start command, and then stopping.

[0042] It should be noted that the continuous mode refers to the thrust component 350 running continuously after receiving the start command, until it stops running after receiving the stop command.

[0043] It should be noted that the high speed, low speed and jog speed are used to control the operating speed of the thrust component 350. They can be switched between each other when needed, and the speed decreases as the product gets closer.

[0044] This utility model discloses a loading control system capable of synchronous lifting and horizontal propulsion. The process of achieving synchronous lifting and horizontal propulsion is as follows: 1. The product is placed and fixed on the loading support 260 of the three sets of lifting platforms 200 by hand. Each set of lifting platforms 200 has two lifting cylinders 210. The operator operates the up and down buttons of the lifting cylinders 210 on the electrical cabinet 100 to control the six lifting cylinders 210 to lift and lower synchronously to adjust the product height. 2. Once the product is at the same height as the cylinder device, the operator manually connects the flange of the product to the coupling 390 of the thrust platform 300 with bolts. The operator then operates the forward button of the thrust platform 300 on the electrical cabinet 100. The drive device 310 drives the thrust platform 300 to move the product forward slowly and horizontally. During the advancement of the thrust platform 300, the friction between the product and the filling support 260 of the lifting platform 200 is much greater than the friction between the slider 250 and the guide rail of the equipment base 500. The product presses against the filling support 260 of the lifting platform 200, moving the lifting platform 200 forward together. 3. When the operator visually observes that the first lifting platform 200 is close to the position of the cylinder device, the operator operates the lowering button of the first lifting cylinder 210 on the electrical cabinet 100. The piston rods of the two lifting cylinders 210 of the first lifting platform 200 retract. After the filling support 260 of the first lifting platform 200 separates from the product, the operator operates the forward button of the thrust platform 300 on the electrical cabinet 100. The thrust platform 300 pushes the product forward. At this time, the first lifting platform 200 in front contacts the cylinder device and stops operating. 4. When the operator visually observes that the second lifting platform 200 is approaching the first lifting platform 200, the operator operates the lowering button of the second lifting cylinder 210 on the electrical cabinet 100. The piston rods of the two lifting cylinders 210 of the second lifting platform 200 retract. After the filling support 260 of the second lifting platform 200 separates from the product, the operator operates the forward button of the thrust platform 300 on the electrical cabinet 100. The thrust platform 300 pushes the product forward. At this time, the second lifting platform 200 contacts the first lifting platform 200 and stops operating. 5. When the operator visually observes that the third lifting platform 200 is approaching the second lifting platform 200, the operator operates the lowering button of the third lifting cylinder 210 on the electrical cabinet 100. The piston rods of the two lifting cylinders 210 of the third lifting platform 200 retract. After the loading support 260 of the third lifting platform 200 separates from the product, the operator operates the forward button of the thrust platform 300 on the electrical cabinet 100. The thrust platform 300 pushes the product forward. At this time, the third lifting platform 200 contacts the second lifting platform 200 and stops operating. 6. The operator then operates the forward button of the thrust platform 300 on the electrical cabinet 100. After the thrust platform 300 pushes the product forward into the cylinder device, the operator then operates the stop button of the thrust platform 300 on the electrical cabinet 100, manually loosens the bolts, and separates the flange of the product from the coupling 390 of the thrust platform 300, thereby completing the product loading.

[0045] The present invention has been described in detail above in a general sense. However, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, any modifications or improvements that do not depart from the spirit of the present invention are within the protection scope of the present invention.

Claims

1. A charge control system enabling simultaneous lifting and horizontal propulsion, characterized by: The loading control system includes a remote upper platform (400); an electrical cabinet (100) includes a control interaction unit (110), a controller (120), a communication unit (130), and an alarm module (140); a lifting platform (200) for adjusting the lifting motion of the equipment includes a lifting cylinder (210), a proportional servo valve (220), a hydraulic station (230), and a displacement sensor (240); and a thrust platform (300) for adjusting the horizontal pushing and pulling motion of the equipment includes a drive device (310), an encoder (320), a tension / compression sensor (330), an intelligent instrument (340), a thrust component (350), and a chain (360) for controlling the motion state of the thrust component (350). The controller (120) is installed in the electrical cabinet (100), and the communication unit (130) is installed in the electrical cabinet (100). The controller (120) and the smart meter (340) are connected via a bus. The communication unit (130) sends the data information collected by the smart meter (340) to the controller (120).

2. A loading control system capable of simultaneous lifting and horizontal propulsion according to claim 1, characterized in that: The lifting platform (200) is slidably connected to the guide rail of the equipment base (500) via a slider (250); a displacement sensor (240) for detecting the position of the lifting cylinder (210) is installed on the lifting cylinder (210), and the displacement sensor (240) is electrically connected to the controller (120); two lifting cylinders (210) are symmetrically installed below the loading support (260), and the piston rod of the lifting cylinder (210) is connected and fixed to the bottom of the loading support (260). The loading support (260) has an arc-shaped structure that is compatible with the shape of the loading material; the hydraulic station (230) provides a power source for the lifting cylinder (210); a proportional servo valve (220) for adjusting the speed and position of the lifting cylinder (210) is installed on the hydraulic station (230) and is connected to the controller (120) and the lifting cylinder (210) respectively.

3. The loading control system capable of simultaneous lifting and horizontal propulsion according to claim 1, characterized in that: The slider 2 (370) at the bottom of the thrust platform (300) is slidably connected to the guide rail of the equipment base (500). The bottom sides of the thrust trolley (380) are connected to the chain (360) by pins. The two ends of the tension and compression sensor (330) used to detect the tension value during the pushing process of the equipment are connected to the chain (360) and the thrust trolley (380) respectively. The tension and compression sensor (330) is electrically connected to the intelligent instrument (340). One end of the coupling (390) is fixed on the thrust trolley (380), and the other end is connected to the loading material. The coupling (390) is a non-telescopic universal joint that can adapt to position deviation. The drive unit (310) is mounted on the equipment base (500). The motor (310-1) is connected to one end of the coupling via a gear reducer (310-2). The other end of the coupling is connected to the drive sprocket (310-3) with a key. The connecting shaft between the drive sprocket (310-3) and the driven sprocket is connected to the equipment base (500) with a bearing. The chain (360) meshes with the drive sprocket (310-3) and the driven sprocket (310-4). The motor (310-1) drives the chain (360) to drive the thrust component (350) to run. The encoder (320) used for closed-loop control of the speed vector of the drive unit (310) is connected to the drive unit (310). The intelligent instrument (340) is mounted on the thrust platform (300), displays the collected tension value of the tension sensor (330), and communicates with the communication unit (130) via serial port.

4. A loading control system capable of synchronous lifting and horizontal propulsion according to claim 1, characterized in that: The control interaction unit (110) is installed inside the electrical cabinet (100), and the control interaction unit (110) is connected to the electrical cabinet (100) via a bus.

5. A loading control system capable of synchronous lifting and horizontal propulsion according to claim 1, characterized in that: The remote host platform (400) is set as an industrial control computer, a laptop computer, or a desktop computer, and sends the loading and running status and information to the cloud.

6. A loading control system capable of synchronous lifting and horizontal propulsion according to claim 1, characterized in that: The alarm module (140) is installed inside the electrical cabinet (100) and is electrically connected to the controller (120); The pressure relief alarm is triggered when the lifting platform (200) experiences pressure relief, causing the lifting cylinder (210) to descend to a threshold value. The synchronization error alarm is triggered when the positional error between multiple lifting cylinders (210) reaches a first threshold during synchronous lifting movements. If the error exceeds a second threshold, the equipment is shut down for protection. The first threshold is less than the second threshold. The tension alarm is triggered when the tension value reaches a set threshold during the forward and backward movement of the thrust component (350), at which point the output of the drive device (310) is stopped.

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