A multi-stage control system for a ring-forming machine
By adjusting motor parameters in real time through a vision inspection unit and a calculation module, the problems of wire redundancy and detection error in multi-stage roller pressing mechanisms are solved, multi-stage roller speed coordination is realized, and the processing efficiency and automation level of the liner forming machine are improved.
Patent Information
- Application Number
- CN202521988610.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-16
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-09-16
AI Technical Summary
In existing technologies, the motor parameters of each stage of the rolling mechanism are manually adjusted to ensure consistent linear speed. This relies on human experience, resulting in low efficiency and a high risk of processing accidents. It also fails to effectively address the issues of redundancy and detection errors in the steel wire between adjacent rolling mechanisms.
A vision inspection unit is used to detect the redundancy of the steel wire in real time. The redundancy deviation is calculated by a calculation module, and the motor parameters are dynamically adjusted to ensure that the speed of the multi-stage pressure rollers is consistent. The integrated control system includes detection, calculation and drive modules. By combining detection error and redundancy, the problems of wire pulling and stacking caused by speed difference are avoided.
This process achieves uniform stress on the steel wire during multi-stage rolling, reduces processing accidents, and improves processing efficiency and the degree of automation of the equipment.
Smart Images
Figure CN224682565U_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of automotive sealing equipment, and more particularly to a multi-stage control system for a ring forming machine. Background Technology
[0002] A ring forming machine is a specialized piece of equipment used to process metal rings. Its core function is to process materials into ring-shaped components through specific processes (such as ring die gear roll forming, bending forming, etc.). That is, it is processed by changing the wall thickness, diameter and cross-sectional shape of the metal ring. It is widely used in machinery, automobile, aerospace and other fields.
[0003] The liner ring is circular in shape, with the ring body formed by double-sided rolling of steel wire to create an alternating groove structure. In the forming process, the smooth steel wire passes through multiple rolling stations, being rolled step by step to form a continuous positive and negative groove structure, and finally coiled to form a spiral columnar semi-finished product similar to a spring. During the rolling forming process, to avoid stress concentration phenomena such as steel wire breakage due to excessive single forming force, multi-stage continuous forming equipment is used. However, because different forming dies are used at each level of the rolling mechanism, the diameter of the dies assembled at each level also varies. This results in differences in the linear speed of the roller shaft rotation at each level of the forming mechanism. Since the forming process requires continuous processing without cutting the steel wire, the motor speeds of each level of the forming mechanism need to be coordinated. Maintaining the same linear speed at each level is to ensure balanced force on the steel wire and to balance the redundancy between adjacent levels of the mechanism. This avoids insufficient redundancy that could pull the steel wire, while also preventing excessive redundancy that could accumulate, entangle, or even get caught in a certain place, affecting continuous processing efficiency.
[0004] In existing technologies, the parameters of each motor are manually adjusted to ensure that the linear speed of each stage of the roller pressing mechanism is the same, so as to avoid problems such as wire pulling and stacking caused by the accumulation of speed differences. However, manual adjustment relies too much on human experience. Different people have different judgment standards, and it requires constant monitoring of the parameter changes of each motor, which consumes manpower. Moreover, considering only the single factor of linear speed, processing accidents can still occur in special cases such as wire snagging.
[0005] Therefore, the technical problem to be solved by this utility model is: how to achieve multi-level roller speed coordination based on the redundancy of steel wires and detection errors between adjacent roller pressing mechanisms, so as to improve processing efficiency and reduce the occurrence of accidents. Utility Model Content
[0006] To address the aforementioned problems, this invention provides a multi-stage control system for a ring forming machine. This system integrates multiple motors controlling the rotation of multi-stage pressure rollers into a single system. A vision detection unit captures images of the steel wire during the roller forming process and transmits these images to a calculation module. The calculation module calculates the amount of steel wire redundancy between adjacent pressure rollers. Based on the deviation between the calculated redundancy and a preset range, the motor parameters are adjusted. Considering detection errors in practical applications, the system comprehensively considers both redundancy and detection errors. Through feedback adjustment, the motor parameters are dynamically adjusted to ensure that the multi-stage pressure rollers rotate at the same speed, thereby avoiding wire pulling and piling problems caused by speed differences and improving processing efficiency.
[0007] To achieve the above objectives, the technical solution adopted by this utility model is as follows: This utility model provides a multi-level control system for a ring forming machine, including a detection module, a calculation module, a control module, and a drive module that are connected in sequence via communication, wherein the drive module is connected to the roller pressing module via transmission. The roller pressing module includes a multi-stage linearly arranged roller pressing mechanism, each stage of which includes a pressure roller. The drive module is a motor, and the pressure roller is connected to the motor for driving the pressure roller to rotate. The motor is electrically connected to the control module. The detection module includes a vision detection unit, which is located directly in front of the roller pressing module and electrically connected to the computing module, and is used to detect the material state between two adjacent roller pressing stages. The material passes through multiple rollers in the roller pressing module in sequence. The rollers are driven by motors to rotate and press the material. The vision detection unit detects the material state between adjacent rollers and transmits the signal to the calculation module. The calculation module calculates whether the material redundancy is within the preset range and transmits the parameters and calculation results to the control module. The control module outputs the adjusted motor parameters to control the motor, and then controls the speed of each roller.
[0008] Furthermore, the vision detection unit is a CCD industrial camera, and each area between two adjacent rolling mechanisms corresponds to one CCD industrial camera.
[0009] Preferably, all CCD industrial cameras are arranged linearly and parallel to the rolling mechanism.
[0010] Furthermore, it also includes a cooling module, which is electrically connected to the control module and is used to cool the pressure roller according to the control signal.
[0011] Furthermore, the detection module also includes a temperature detection unit, which is fixed on each stage of the pressure rollers. The temperature detection unit is used to detect the temperature of the pressure rollers and transmit signals to the calculation module. If the temperature of the pressure rollers is detected to be too high, the control module transmits signals to the cooling module to cool the pressure rollers.
[0012] Preferably, the temperature detection unit is a temperature sensor.
[0013] The beneficial effects of this utility model are as follows: This invention provides a multi-level control system for a ring forming machine, integrating multiple motors controlling the rotation of multi-level pressure rollers into a single system. It innovatively proposes a new technical solution: a vision detection unit captures images of the steel wire during the roller forming process and transmits them to a calculation module. The calculation module calculates the amount of steel wire redundancy between adjacent pressure rollers. Based on the deviation between the calculated redundancy and a preset range, the motor parameters are adjusted. Considering the detection errors in practical applications—that is, the deformation and elasticity of the wire vary during different roller forming processes—the system comprehensively considers both redundancy and detection errors. Through feedback adjustment, the motor parameters are dynamically adjusted to ensure that the speeds of the multi-level pressure rollers are the same, thereby avoiding wire pulling and stacking problems caused by speed differences and improving processing efficiency. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the multi-level control system framework for a ring forming machine according to this utility model. Detailed Implementation
[0015] The technical solution of this application will be clearly and completely described below.
[0016] This invention, based on existing technology, integrates multiple motors controlling the rotation of multi-stage pressure rollers into a single system. It innovatively proposes a new technical solution: a vision detection unit captures images of the steel wire during the roller forming process and transmits them to a calculation module. The calculation module calculates the redundancy of the steel wire between adjacent pressure rollers and adjusts the motor parameters based on the deviation between the calculated redundancy and a preset range. This approach considers the detection errors in practical applications (the deformation and elasticity of the wire vary during different roller forming processes; in conventional multi-motor linkage control systems, the steel wire is subjected to...) in the first-stage roller forming mechanism... The first stage has the greatest pressure and deformation, making it the most speed-limited stage for the roller pressing mechanism. Even if the motor parameters of the first stage are set the same as those of the subsequent stages, the speed of the first stage roller pressing mechanism will still be slightly slower in actual use due to the limitation. Over time, this will gradually reduce the wire redundancy between the first and second stage roller pressing mechanisms. In this invention, the speed of the first stage roller is used as a reference to adjust the speed of the subsequent stages of motors to balance the linear speed. Taking into account the redundancy and detection error, the motor parameters are dynamically adjusted through feedback to make the speed of the multi-stage pressing rollers the same, thereby avoiding the problems of wire pulling and stacking caused by speed difference and improving processing efficiency.
[0017] For details, please refer to Figure 1As shown, this utility model provides a multi-level control system for a ring forming machine, including a detection module, a calculation module, a control module, and a drive module that are connected in sequence via communication. The drive module is connected to the roller pressing module via transmission. The roller pressing module includes a multi-stage linearly arranged roller pressing mechanism, each stage of which includes a pressure roller. The drive module is a motor, and the pressure roller is connected to the motor for driving the pressure roller to rotate. The motor is electrically connected to the control module. The detection module includes a vision detection unit, which is located directly in front of the roller pressing module and electrically connected to the computing module, and is used to detect the material state between two adjacent roller pressing stages. The material passes through multiple rollers in the roller pressing module in sequence. The rollers are driven by motors to rotate and press the material. The vision detection unit detects the material state between adjacent rollers and transmits the signal to the calculation module. The calculation module calculates whether the material redundancy is within the preset range and transmits the parameters and calculation results to the control module. The control module outputs the adjusted motor parameters to control the motor, and then controls the speed of each roller.
[0018] This invention features a visual inspection unit to detect the steel wires during the rolling process. By calculating whether the steel wire redundancy between two adjacent rolling mechanisms is within a suitable range, the motor parameters are adjusted to control the speed of the pressure rollers. The motor parameter adjustment is fast and accurate, the device has a simple structure, and is easy to use.
[0019] The visual inspection unit is a CCD industrial camera, and each area between two adjacent rolling mechanisms corresponds to one CCD industrial camera.
[0020] Multiple CCD industrial cameras are used to detect the material between adjacent roller pressing mechanisms. Their high image stability, high transmission capacity, and high anti-interference capability can effectively improve the detection accuracy.
[0021] Preferably, all CCD industrial cameras are arranged linearly and parallel to the rolling mechanism.
[0022] By setting linearly arranged CCD industrial cameras parallel to the rolling mechanism, the distance between each CCD industrial camera and the steel wire between the two adjacent rolling mechanisms is equal. This allows for the setting of uniform parameter standards, making it easier to adjust camera parameters.
[0023] It also includes a cooling module, which is electrically connected to the control module and is used to cool the pressure roller according to the control signal.
[0024] By installing a cooling module, the stable operation of the pressure roller mechanism can be ensured, and work efficiency can be avoided due to excessive temperature.
[0025] The detection module also includes a temperature detection unit, which is fixed on each stage of the pressure rollers. It is used to detect the temperature of the pressure rollers and transmit signals to the calculation module. If the temperature of the pressure rollers is too high, the control module transmits signals to the cooling module to cool the pressure rollers.
[0026] In practical applications, the normal operating temperature threshold of the pressure roller can be set according to the specific working type. Once the temperature of the pressure roller is detected to exceed the preset threshold, the control module transmits a control signal to the cooling module to cool the pressure roller in time, ensuring the smooth operation of the work.
[0027] Preferably, the temperature detection unit is a temperature sensor.
[0028] The working process of this utility model is as follows: The material used in this invention is smooth steel wire. The smooth steel wire passes through multiple roller pressing mechanisms, being rolled step-by-step to form a continuous positive and negative groove structure. During the rolling and shaping process, a vision detection unit captures real-time images of the steel wire between adjacent roller pressing mechanisms and transmits these images to a calculation module. The calculation module calculates the redundancy based on the steel wire identified in the images and compares the calculated redundancy with a preset redundancy range. Based on the comparison result, a corresponding strategy is executed. Specifically, if the calculated redundancy falls within the preset range, no adjustment is made, and the current state is maintained. If the calculated redundancy does not fall within the preset range, the motor parameters are adjusted according to the deviation between the calculated redundancy and the preset range. The motor controls the roller speed according to the adjusted parameters, achieving real-time monitoring and adjustment of the roller speed. This effectively avoids wire pulling and piling problems caused by speed differences, improving processing efficiency.
[0029] Considering the errors in actual operation, the steel wire experiences the greatest pressure when passing through the first-stage roller pressing mechanism, which means that the speed of the first-stage roller is most restricted. When adjusting the motor parameters, the parameters of the first-stage motor can be adjusted appropriately to ensure that the actual speed of all rollers is consistent.
[0030] In the initial state, this utility model can directly allocate the output speed of each motor by setting the linear speed and inputting the parameters of each mold. In the overall shutdown state, the rotation state of any motor of the mechanism can be manually fine-tuned, which is convenient for maintenance and manual fine-tuning.
[0031] It should be noted that this invention does not make any improvements to the algorithm; that is, identifying the steel wire in the image and calculating the redundancy are both achievable by existing algorithms. Specifically, for example: The visual inspection unit acquires images of the steel wire between two adjacent pressure rollers and transmits them to the calculation module. The calculation module uses existing image recognition algorithms to identify the steel wire. First, it performs feature extraction to identify and separate the steel wire from the background in the image, and determines the pixel contour, length, and position coordinates of the steel wire in the image. At the same time, it extracts the edge coordinates of the two adjacent pressure rollers as a reference.
[0032] Based on the preset pixel-to-actual length correspondence of the camera, the pixel length of the steel wire in the image is converted into the actual physical length (denoted as L1). The center distance between two adjacent pressure rollers (a fixed physical parameter in the equipment design, pre-stored in the calculation module, denoted as L0) is the theoretical length of the steel wire in the state without redundancy. The difference between the actual length and the theoretical length is calculated to obtain the redundancy amount ΔL. The calculation module compares ΔL with the preset reasonable redundancy range [ΔL_min, ΔL_max] to determine whether the current redundancy amount is normal, and sets ΔL_min>0 to avoid the steel wire from breaking due to lack of redundancy during the rolling process.
[0033] When the redundancy ΔL calculated by the calculation module does not fall within the preset range, the control module will dynamically adjust the corresponding motor parameters based on the deviation between the redundancy ΔL and the preset range, combined with the first-stage roller speed. The specific rules are as follows: When ΔL > ΔL_max (excessive redundancy), the cause may be that the speed of the subsequent pressure roller is too slow, causing the steel wire conveyed by the previous pressure roller to be unable to be pulled in time, resulting in accumulation and loosening. In this case, increase the speed of the subsequent motor: according to the magnitude of the deviation value (ΔL - ΔL_max), increase the output speed of the subsequent motor proportionally until ΔL falls back to the preset range.
[0034] When ΔL < ΔL_min (insufficient redundancy), the cause may be that the speed of the downstream pressure roller is too fast, causing the steel wire conveyed by the upstream pressure roller to be overstretched, resulting in tension and breakage risk. In this case, reduce the speed of the downstream motor: according to the magnitude of the deviation value (ΔL_min-ΔL), reduce the output speed of the downstream motor proportionally until ΔL returns to the preset range.
[0035] The visual inspection unit captures images at high frequency, the calculation module updates the redundancy ΔL in real time, and the control module dynamically corrects the motor parameters based on the latest deviation value, avoiding speed fluctuations caused by large-scale adjustments at once. Furthermore, when adjusting motor parameters, an error compensation coefficient matching the current rolling pressure level is pre-added to ensure that the actual speed adjustment effect is consistent with the theoretical result. During shutdown maintenance or special operating conditions, the speed of any motor level can be manually fine-tuned as a supplement to automatic adjustment, further optimizing the redundancy control accuracy.
[0036] The above embodiments are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.
Claims
1. A multi-level control system for a ring forming machine, characterized in that, It includes a detection module, a calculation module, a control module, and a drive module that are connected in sequence via communication, and the drive module is connected to the roller pressing module via transmission. The roller pressing module includes a multi-stage linearly arranged roller pressing mechanism, each stage of which includes a pressure roller. The drive module is a motor, and the pressure roller is connected to the motor for driving the pressure roller to rotate. The motor is electrically connected to the control module. The detection module includes a vision detection unit, which is located directly in front of the roller pressing module and electrically connected to the computing module, and is used to detect the material state between two adjacent roller pressing stages. The material passes through multiple stages of pressure rollers in the roller pressing module in sequence. The pressure rollers are driven by motors to rotate and press the material. The vision detection unit detects the material state between adjacent pressure rollers and transmits the signal to the calculation module. The calculation module calculates whether the material redundancy is within the preset range and transmits the parameters and calculation results to the control module. The control module outputs the adjusted motor parameters to control the motor, and then controls the speed of each stage of pressure rollers.
2. The multi-level control system for a ring forming machine according to claim 1, characterized in that, The visual inspection unit is a CCD industrial camera, and each area between two adjacent rolling mechanisms corresponds to one CCD industrial camera.
3. The multi-stage control system for a ring forming machine according to claim 2, characterized in that, All the CCD industrial cameras are arranged linearly and parallel to the rolling mechanism.
4. The multi-stage control system for a ring forming machine according to claim 1, characterized in that, It also includes a cooling module, which is electrically connected to the control module and is used to cool the pressure roller according to the control signal.
5. The multi-level control system for a ring forming machine according to claim 1, characterized in that, The detection module also includes a temperature detection unit, which is fixed on each stage of the pressure rollers. It is used to detect the temperature of the pressure rollers and transmit signals to the calculation module. If the temperature of the pressure rollers is too high, the control module transmits signals to the cooling module to cool the pressure rollers.
6. The multi-stage control system for a ring forming machine according to claim 5, characterized in that, The temperature detection unit is a temperature sensor.