A smart protection device for identifying and preventing abnormal beats

Abstract

This utility model discloses an intelligent identification and protection device for abnormal stamping beats, relating to the field of stamping equipment technology. It includes a PLC encoder body, with a first wiring module soldered to the outer wall of the PLC encoder body via pins, and a second wiring module soldered to the outer wall of the PLC encoder body via pins. This protection device, through collaboration between the PLC encoder body and a signal processing circuit board, uses a sliding window algorithm to dynamically analyze the stamping beat, automatically identifying abnormal conditions such as excessively fast / slow continuous beats and sudden stops. This overcomes the lag of traditional manual monitoring, achieving intelligent monitoring of the stamping beat, thus fulfilling the purpose of an intelligent identification and protection device for abnormal stamping beats.

Description

Technical Field

[0001] This utility model relates to the field of stamping equipment technology, specifically to an intelligent identification and protection device for abnormal rhythm. Background Technology

[0002] Currently available equipment only has a counting function and lacks automatic identification of abnormal cycle times, relying on manual observation, which poses safety hazards; it cannot quickly stop the machine when an abnormality occurs, leading to the risk of worker injury or equipment damage; the counting of stamping times depends on manual observation and recording, which is inefficient and prone to errors. Utility Model Content

[0003] (a) Technical problems to be solved

[0004] To address the shortcomings of existing technologies, this utility model provides an intelligent beat anomaly identification and protection device, which solves the problem that existing devices only have a counting function but lack automatic beat anomaly identification function.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, this utility model is implemented through the following technical solution: A beat anomaly intelligent identification and protection device, comprising: a PLC encoder body, wherein a first wiring module is soldered to the pads on the outer wall of the PLC encoder body via pins; the PLC encoder body is a Lujie Technology brand, specifically a Lujie MS / YFL series programmable controller; the PLC encoder is fixed to the side of the punch press frame by bolts; the terminal module is exposed outside the device housing for connecting to external circuits; a second wiring module is soldered to the pads on the outer wall of the PLC encoder body via pins; a signal processing circuit board is soldered to the signal output port of the PLC encoder body; the signal processing circuit board receives the encoded signal from the PLC encoder body and performs filtering, amplification, and digital conversion processing on the position encoded signal.

[0007] Preferably, the first wiring module includes: port 1, port 2, port 3, port 4 and port 5, the outer wall of port 1 is connected to the positive terminal of a 24V DC power supply through a conductive connecting wire, and the outer wall of port 2 is connected to the negative terminal of a 24V DC power supply through a conductive connecting wire.

[0008] Preferably, the outer wall of port number three is connected to a punch press cam switch via a conductive connecting wire. The cam signal acquisition end of the PLC encoder is connected to the punch press cam shaft via a coupling or gear meshing to ensure that a signal can be triggered when the cam rotates. The outer wall of port number four is connected to a normally open contact of a blue button via a conductive connecting wire. The outer wall of port number five is connected to a foot switch via a conductive connecting wire.

[0009] Preferably, the second wiring module includes port 6, port 7 and port 8. The outer wall of port 6 is connected to the negative terminal of a 24V DC power supply via a conductive connecting wire. A blue button indicator light is connected to the outer wall of port 6 via a conductive connecting wire. The outer wall of port 8 is connected to a punch press emergency stop circuit via a conductive connecting wire.

[0010] (III) Beneficial Effects

[0011] This invention provides an intelligent identification and protection device for abnormal beats. It has the following beneficial effects:

[0012] (I) This kind of intelligent identification and protection device for abnormal pressing beats, through the collaboration of the PLC encoder body and the signal processing circuit board, adopts the sliding window algorithm to dynamically analyze the pressing beats, and can automatically identify abnormal working conditions such as continuous beats that are too fast / too slow and sudden stops. It changes the lag of traditional manual monitoring, realizes intelligent monitoring of pressing beats, and makes abnormal identification no longer dependent on manual observation, thus improving the timeliness and accuracy of monitoring.

[0013] (II) When an abnormality is detected, the device can immediately activate a safety response, send a signal to the emergency stop circuit of the punch press through the wiring module to cut off the main power supply, lock the foot switch and trigger the indicator light alarm, forming a rapid safety protection mechanism to avoid threats to worker safety due to abnormal equipment operation and provide safety assurance for stamping operations.

[0014] (III) The intelligent identification and protection device for abnormal cycle time collects data to establish a dynamic reference parameter library during initial operation. After fault reset, it can collect data again to update the reference. It can automatically adjust the reference parameters according to different stamping conditions without frequent manual settings, which enhances its adaptability to different materials, molds and other production conditions, and enables the device to work stably under various working conditions. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the main body of the PLC encoder of this utility model;

[0016] Figure 2 This is a flowchart of the debugging mode of this utility model;

[0017] Figure 3 This is a flowchart of the counting mode of this utility model.

[0018] In the diagram: 1. PLC encoder body; 2. Port 6; 3. Port 7; 4. Port 8; 6. Port 1; 7. Port 2; 8. Port 3; 9. Port 4; 10. Port 5; 11. Signal processing circuit board; 12. First wiring module; 13. Second wiring module. Detailed Implementation

[0019] 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.

[0020] Please see Figure 1-3 This utility model provides a technical solution: an intelligent identification and protection device for abnormal punching rhythm, comprising: a PLC encoder body 1, a first wiring module 12 soldered to the pads on the outer wall of the PLC encoder body 1 via pins, a microprocessor integrated inside the PLC encoder body 1 with a pre-loaded punching rhythm analysis program in its storage module, and a second wiring module 13 soldered to the pads on the outer wall of the PLC encoder body 1 via pins. Upon detecting an abnormal punching rhythm, the PLC encoder body 1 immediately activates a three-level safety response mechanism. First, a control signal is sent to the emergency stop circuit of the punch press through port 4 of the second wiring module 13 to cut off the main power supply to the punch press, causing the punch press to stop running. A signal processing circuit board 11 is soldered to the signal output port of the PLC encoder body 1. The signal processing circuit board 11 receives the encoded signal from the PLC encoder body 1 and performs filtering, amplification, and digital conversion processing on the position encoded signal.

[0021] The first wiring module 12 includes: port 6, port 7, port 8, port 9, and port 10. The outer wall of port 6 is connected to the positive terminal of a 24V DC power supply via a conductive wire. The outer wall of port 7 is connected to the negative terminal of a 24V DC power supply via a conductive wire. The outer wall of port 8 is connected to a punch press cam switch via a conductive wire. The outer wall of port 9 is connected to the normally open contact of a blue button via a conductive wire. The outer wall of port 10 is connected to a foot switch via a conductive wire. After troubleshooting, the operator presses and holds the blue button to send a reset signal to the PLC encoder body 1 through port 10. The PLC encoder body 1 clears the fault state, and the system re-enters the reference data acquisition mode.

[0022] The second wiring module 13 includes port 2 (six), port 3 (seven), and port 4 (eight). The outer wall of port 2 (six) is connected to the negative terminal of a 24-volt DC power supply via a conductive wire. A blue button indicator light is connected to the outer wall of port 2 (six) via a conductive wire. The outer wall of port 4 (eight) is connected to a punch press emergency stop circuit via a conductive wire.

[0023] In the field of modern stamping processing, ensuring worker safety and stable equipment operation are crucial aspects of the production process. Traditional stamping equipment relies on manual monitoring of the stamping cycle, which suffers from problems such as delayed response and significant safety hazards. To address this, an intelligent identification and protection device for abnormal cycle time has emerged. This device, through the coordinated operation of the PLC encoder body 1, wiring module, and signal processing circuit board 11, achieves real-time monitoring, abnormal identification, and safety protection of the stamping cycle time. Its working principle is as follows:

[0024] When the device is started, the operator first connects the 24V DC power supply. The power supply forms a circuit through port 6 of the first wiring module 12 and port 7 of the second wiring module 12 to supply power to the PLC encoder body 1 and each sensor. At this time, port 2 of the second wiring module 13 forms a circuit with the blue button indicator light. The indicator light is constantly lit, indicating that the power supply is normal. When the blue button is pressed, its normally open contact sends a start signal to the PLC encoder body 1 through port 9 of the first wiring module 12. The system enters the self-test state. The PLC encoder body 1 initializes and verifies the internal circuits and sensors to ensure that each module functions normally.

[0025] During the baseline data acquisition phase, the worker presses the foot switch, and the signal is input to the PLC encoder body 1 through port 10 of the first wiring module 12, triggering the action of the punch press cam switch. The cam switch installed at the punch press cam mechanism feeds back the position signal to the PLC encoder body 1 through port 8 of the first wiring module 12. The PLC encoder body 1 records the cycle time of a single punch. The system continuously collects punch data for five minutes, and the original signal is filtered, amplified, and digitally converted by the signal processing circuit board 11 to establish a dynamic baseline parameter library, determine the average cycle time and the safety threshold range of ±10%, and provide a reference for subsequent real-time monitoring.

[0026] After the device enters normal operation, the PLC encoder body 1 analyzes and processes the real-time stamping data based on the sliding window algorithm. Whenever the worker presses the foot switch, the foot switch signal is input to the PLC encoder body 1 through port 5 (10). At the same time, the punch press cam switch is activated, and the position signal is fed back through port 3 (8). The PLC encoder body 1 calculates the cycle time of this stamping operation and compares it with a reference threshold.

[0027] The device is set with three abnormal judgment conditions: if the stamping cycle time is less than the lower limit of the reference value for three consecutive stamping cycles, it is judged as too fast; if the stamping cycle time is greater than the upper limit of the reference value for three consecutive stamping cycles, it is judged as too slow; if the interval between two stamping cycles exceeds three times the average of the reference value, it is judged as a sudden stop. The signal processing circuit board 11 receives the encoded signal output by the PLC encoder body 1 in real time, performs further processing and analysis on the signal, and assists the PLC encoder body 1 in accurately identifying abnormal situations.

[0028] Once an abnormal stamping cycle is detected, the PLC encoder body 1 immediately activates a three-level safety response mechanism. First, it sends a control signal to the press emergency stop circuit through port 4 of the second wiring module 13 to cut off the press's main power supply and stop the press from running. At the same time, it locks the foot switch input signal to prevent accidental restart of the equipment. In addition, the PLC encoder body 1 controls the blue button indicator light to form a new circuit with the power supply through port 2, causing the indicator light to change from solid to flashing red, alerting the operator that an abnormality has occurred.

[0029] After troubleshooting, the operator presses and holds the blue button to send a reset signal to the PLC encoder body 1 through port 5 (10). The PLC encoder body 1 clears the fault state, and the system re-enters the reference data acquisition mode. At this time, the device collects stamping data for another five minutes, updates the reference parameter library, and ensures that the device adapts to the current production conditions, providing accurate monitoring and protection for subsequent stamping operations.

[0030] The PLC encoder body 1 serves as the core control unit of the device, responsible for data acquisition, logic judgment, and instruction output. The first wiring module 12 and the second wiring module 13 serve as electrical connection hubs, enabling signal transmission between the PLC encoder body 1 and the power supply, sensors, and actuators. The signal processing circuit board 11 optimizes the encoded signals output by the PLC encoder body 1, improving the accuracy and reliability of the data.

[0031] Throughout the entire operation, a 24V DC power supply provides a stable power supply to all components through ports 1-6, 2-7, and 6-2; the punch press cam switch provides real-time feedback of the punching position signal through port 3-8; the foot switch inputs manual operation signals through port 5-10; the blue button inputs start and reset signals through port 4-9; the blue button indicator light displays the device's operating status through ports 6-2 and 7-3; and the punch press emergency stop circuit receives stop commands through port 8-4. All components are connected through wiring modules to form an organic whole, working together to achieve intelligent monitoring and safety protection of the punching cycle.

[0032] This intelligent identification and protection device for abnormal cycle time solves the shortcomings of traditional stamping equipment in cycle time monitoring through the above working principle, realizes automated and intelligent monitoring of the stamping process, improves the safety and reliability of stamping processing, and provides strong technical support for modern stamping production.

[0033] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0034] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A beat anomaly intelligent identification protection device, characterized in that, Including: PLC encoder body (1), the first wiring module (12) is welded with the pad of the outer wall of the PLC encoder body (1) through pin, the second wiring module (13) is welded with the pad of the outer wall of the PLC encoder body (1) through pin, the signal output port of the PLC encoder body (1) is welded with signal processing circuit board (11), the signal processing circuit board (11) receives the encoding signal from the PLC encoder body (1), and the position encoding signal is filtered, amplified and digitized conversion processing.

2. The beat anomaly intelligent recognition protection device according to claim 1, characterized in that: The first wiring module (12) includes: a first port (6), a second port (7), a third port (8), a fourth port (9) and a fifth port (10), the outer wall of the first port (6) is connected with the positive electrode of 24V DC power supply through conductive connecting line, the outer wall of the second port (7) is connected with the negative electrode of 24V DC power supply through conductive connecting line.

3. The intelligent beat anomaly recognition protection device according to claim 2, characterized in that: The outer wall of the third port (8) is connected with the punch cam switch through the conductive connecting line, the outer wall of the fourth port (9) is connected with the normally open contact of the blue button through the conductive connecting line, and the outer wall of the fifth port (10) is connected with the foot switch through the conductive connecting line.

4. The intelligent beat anomaly recognition protection device according to claim 1, characterized in that: The second wiring module (13) includes a sixth port (2), a seventh port (3) and an eighth port (4), the outer wall of the sixth port (2) is connected with the negative electrode of 24V DC power supply through conductive connecting line, and the outer wall of the sixth port (2) is connected with the blue button indicator lamp through conductive connecting line.

5. The intelligent beat anomaly recognition protection device according to claim 4, characterized in that: The outer wall of the eighth port (4) is connected with the punch emergency stop circuit through the conductive connecting line.

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