CN108333979B - Counterweight type loop control system and method - Google Patents
Counterweight type loop control system and method Download PDFInfo
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- CN108333979B CN108333979B CN201711394279.6A CN201711394279A CN108333979B CN 108333979 B CN108333979 B CN 108333979B CN 201711394279 A CN201711394279 A CN 201711394279A CN 108333979 B CN108333979 B CN 108333979B
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- 238000001514 detection method Methods 0.000 claims abstract description 5
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
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Abstract
The invention provides a counterweight type loop control system and a counterweight type loop control method, wherein the system comprises a loop front motor, a main command motor driver for driving a main command motor of a production line, a loop front motor intelligent driver for driving the loop front motor to operate, a loop position sensor for detecting a loop amount signal, a loop amount overrun sensor group for monitoring the over-charge and over-discharge of the loop amount, and a man-machine interaction interface for controlling the loop front motor through the loop front motor intelligent driver and displaying the current operation state and an audible and visual alarm signal; the method mainly comprises the steps that an intelligent driver of the loop front motor calculates a given value of the rotation speed of the loop front motor by receiving the rotation speed of the main motor and a detection signal sent by a loop position sensor, correspondingly adjusts the rotation speed of the loop front motor, and the like. The invention has simple structure, lower cost and convenient realization and maintenance, and realizes the switching and automatic synchronous control of the counterweight loop control mode with lower cost.
Description
Technical Field
The invention relates to the field of control of loop mechanisms of continuous processing production lines, in particular to a counterweight loop control system and a counterweight loop control method.
Background
In a continuous processing production line of coiled materials, in order to realize continuous operation without stopping, a loop mechanism is usually arranged at an inlet section, an outlet section or a process section of the production line, and the loop mainly realizes storage and buffering of the coiled materials and is used for feeding and discharging coils at the inlet section/the outlet section of the production line or ensuring the constant tension of the process section. For a loop mechanism with low main speed and small dynamic change of speed of a production line, a counterweight loop is usually adopted. The control system of the counterweight type loop mainly realizes the balance of the loop amount and the synchronous operation of the front section and the rear section of the loop, and simultaneously has the functions of manually/automatically filling and discharging the loop, over-limit protection of the loop amount and the like.
At present, a control system of the counterweight type loop mostly adopts a completely manual control device or is provided with an independent controller, and the control requirement is met by controlling a front motor of the loop. The fully manual control device has the problems that the process speed difference of the front section and the rear section of the loop is difficult to match, the dynamic change of the loop tension is overlarge, production accidents are easy to cause, the product quality is influenced, meanwhile, the manual operation strength is high, the operation errors are more, and the continuous and stable production is not facilitated; the control system formed by the completely independent control device has the problems of high equipment cost, complex system, difficult fault detection and the like.
Disclosure of Invention
The purpose of the invention is that: the counterweight type loop control system is simple in structure, low in cost and convenient to implement and maintain, can effectively control the manual/automatic charging and discharging operation of the loop and the synchronous operation of the front section and the rear section of the loop when in use, and has the function of over-limit protection of the loop amount.
Another object of the present invention is to provide a control method implemented by the counterweight loop control system, so as to ensure the quick response and stability of the loop during the automatic charging and discharging and synchronous operation processes.
The technical scheme of the invention is as follows: the invention relates to a counterweight loop control system, which comprises a loop front motor and a main command motor driver for driving a main command motor of a production line, and is structurally characterized in that: the control system further comprises a loop pre-motor intelligent driver for driving the loop pre-motor to operate, a loop position sensor for detecting a loop amount signal, a loop amount overrun sensor group for monitoring the over-charge and over-discharge of the loop amount, and a man-machine interaction interface for controlling the loop pre-motor through the loop pre-motor intelligent driver and displaying the current operation state and the audible and visual alarm signal;
the master motor driver is provided with a master motor speed feedback output end and a master motor stopping signal input end; the intelligent driver of the looper prepositive motor is provided with a signal interface board, and the signal interface board is provided with at least 12 signal input/output interfaces; the sleeve amount overrun sensor group comprises a sleeve amount overcharge parking sensor, a sleeve amount overcharge alarm sensor, a sleeve amount overdischarge alarm sensor and a sleeve amount overdischarge parking sensor; the man-machine interaction interface is provided with a manual/automatic mode signal output end, a motor forward rotation/reverse rotation signal output end, a inching/rotation speed signal output end, an operation state signal input end and an audible and visual alarm signal input end;
the master electricity speed feedback output end and the master electricity stopping signal input end of the master electricity motor driver are respectively and electrically connected with 1 signal input interface and 1 signal output interface corresponding to the signal interface board of the intelligent loop motor driver; the signal output ends of the 4 sensors of the loop position sensor and the loop amount overrun sensor group are respectively and electrically connected with corresponding signal input interfaces on a signal interface board of the intelligent driver of the loop front motor; the manual/automatic mode signal output end of the man-machine interaction interface, the forward/reverse rotation signal output end of the motor and the inching/rotating speed signal output end are respectively and electrically connected with corresponding signal input interfaces on a signal interface board of the intelligent driver of the loop front motor; the operation state signal input end and the audible and visual alarm signal input end of the man-machine interaction interface are respectively and electrically connected with corresponding signal output interfaces on a signal interface board of the intelligent driver of the loop front-end motor.
The further scheme is as follows: the intelligent driver of the looper front-end motor is a frequency converter or a servo controller with settable parameters.
The further scheme is as follows: the loop position sensor is arranged on the idler roller which is provided with the counterweight loop and rotates along with the idler roller so as to output a corresponding loop amount signal.
The further scheme is as follows: the 4 sensors of the sleeve amount overrun sensor group are arranged on the counterweight type loop.
The further scheme is as follows: the control system also comprises an upper production line main control computer, the intelligent loop motor driver is provided with a communication interface, and the intelligent loop motor driver is in information interaction with the production line main control computer through the communication interface.
The automatic charging and discharging sleeve of the counterweight loop and the control method for synchronous operation implemented by the counterweight loop control system comprise the following steps:
(1) the man-machine interaction interface sends an automatic mode instruction to the intelligent driver of the loop front motor;
(2) the man-machine interaction interface enables the loop front motor to run opposite to the production line main command motor by selectively setting the forward rotation or the reverse rotation of the loop front motor;
(3) the intelligent driver of the loop prepositive motor receives the detection signal sent by the loop position sensor in real timeV offset Master motor operation speed fed back by master motor driverV 0 ；
(4) The intelligent driver of the loop front motor adopts the method (1) to calculate the rotating speed of the loop front motorV 1 Is set at a given value of:
V 1 =K a (V 0 +K b K c (V offset -U ref / 2 + U 0 ) ) （1）
wherein the method comprises the steps of the process comprises,U ref a reference voltage for the loop position sensor output signal,U 0 for regulating the amount of the loop in steady stateU ref / 2 + U 0 ) The value is optimally determined during production line debugging and is set in a parameter set of the intelligent driver of the loop front-end motor; coefficients ofK c The ratio of the rotating speed amplitude of the loop front motor to the feedback signal amplitude of the loop position sensor; coefficients ofK b Is used for adjusting the speed of sleeve filling and sleeve discharging,K b K c the value is optimally determined during production line debugging and is set in a parameter set of the intelligent driver of the loop front-end motor; coefficients ofK a Setting a transmission ratio between a main motor and a loop front motor of a production line in a parameter group of an intelligent driver of the loop front motor;
(5) the intelligent driver of the looper front motor obtains the rotation speed according to calculationV 1 Regulating and outputting the given value of the control loop front motor according to the rotation speedV 1 Is rotated by a given value; meanwhile, the intelligent driver of the loop prepositive motor judges whether the current loop reaches the set loop amount, if not, the step (3) is returned; if yes, the intelligent driver of the loop pre-motor controls the loop pre-motor to rotate according to the current rotation speedV 1 Is rotated by a given value of (a).
The invention has the positive effects that: (1) The main control device of the counterweight type loop control system utilizes the existing loop front motor intelligent driver and the production line main motor driver on the production line, and only a man-machine interaction interface, a loop position sensor and a loop amount overrun sensor group are added on the basis, so that the counterweight type loop control mode switching, automatic charging and discharging and synchronous operation control can be realized with extremely low software and hardware cost, and the counterweight type loop control system has the advantages of low cost, high automation degree, simplicity and reliability in system and the like. (2) The counterweight type loop control system can optimize the operation parameters of the system by adjusting the parameter set in the intelligent driver of the loop front motor when in use, and is convenient and flexible to maintain. (3) The present invention provides a weight-type loop control system which, when a loop deviates from a set loop in performing controlMeasuring amountThe larger the loop is, the faster the loop returns to the set loop amount, and when the loop approaches the set loop amount, the return speed of the loop is also approaching zero, so that the system control has certain self-adaptability.
Drawings
Fig. 1 is a schematic structural view of the present invention.
The reference numerals in the above figures are as follows:
the intelligent control device comprises a loop pre-motor 1, a main command motor driver 2, a loop pre-motor intelligent driver 3, a signal interface board 31, a loop position sensor 4, a loop amount overrun sensor group 5, a man-machine interaction interface 6 and a production line main control computer 7.
Detailed Description
The invention will be described in further detail with reference to the drawings and the detailed description.
Example 1
Referring to fig. 1, the counterweight type loop control system of the embodiment is illustrated by taking a counterweight type loop control system for transmission control of a continuous web processing production line as an example, and the counterweight type loop control system mainly comprises a loop front motor 1, a main command motor driver 2, a loop front motor intelligent driver 3, a loop position sensor 4, a loop amount overrun sensor group 5 and a man-machine interaction interface 6.
The loop pre-motor 1 is used for performing charging and discharging operation on a counterweight loop on a production line, and the loop pre-motor 1 is provided with a driving control signal input end;
the main command motor driver 2 is used for driving a main command motor for driving the production line to run, and the main command motor driver 2 is provided with a main command motor speed feedback output end and a main command motor stop signal input end;
the intelligent loop motor driver 3 is used for driving the loop motor 1 to run; the intelligent driver 3 of the looper prepositive motor is provided with a signal interface board 31, and the signal interface board 31 is provided with at least 12 signal input/output interfaces; the intelligent driver 3 of the looper front motor is an intelligent driver such as a frequency converter and a servo controller with settable parameters.
The loop position sensor 4 is arranged on an idler roller which is provided with a counterweight loop and rotates along with the idler roller, and outputs a corresponding loop amount signal;
the sleeve amount overrun sensor group 5 comprises a sleeve amount overcharge parking sensor, a sleeve amount overcharge alarm sensor, a sleeve amount overdischarge alarm sensor and a sleeve amount overdischarge parking sensor, wherein the 4 sensors are arranged on a counterweight type loop and used for monitoring the overcharge overdischarge of the sleeve amount;
the man-machine interaction interface 6 is used for controlling the loop pre-motor 1 through the loop pre-motor intelligent driver 3 and displaying the current running state and the audible and visual alarm signals; the man-machine interaction interface 6 is provided with a manual/automatic mode signal output end, a motor forward rotation/reverse rotation signal output end, a inching/rotation speed signal output end, an operation state signal input end and an audible and visual alarm signal input end;
the loop front motor 1 is electrically connected with the loop front motor intelligent driver 3; the master electricity speed feedback output end and the master electricity stopping signal input end of the master motor driver 2 are respectively and electrically connected with 1 signal input interface and 1 signal output interface corresponding to the signal interface board 31 of the intelligent loop motor driver 3; the signal output ends of the loop position sensor 4 and the 4 sensors of the loop amount overrun sensor group 5 are respectively and electrically connected with corresponding signal input interfaces on the signal interface board 31 of the intelligent driver 3 of the loop front motor; the manual/automatic mode signal output end, the motor forward rotation/reverse rotation signal output end and the inching/rotation speed signal output end of the man-machine interaction interface 6 are respectively and electrically connected with corresponding signal input interfaces on the signal interface board 31 of the intelligent loop motor driver 3; the running state signal input end and the audible and visual alarm signal input end of the man-machine interaction interface 6 are respectively and electrically connected with corresponding signal output interfaces on the signal interface board 31 of the intelligent driver 3 of the loop front motor.
The working principle and the process of the counterweight loop control system of the embodiment are briefly described as follows:
when the intelligent driver 3 of the front-end motor of the loop detects that the man-machine interaction interface 6 sets the control mode to be a manual mode during the operation of the system, the intelligent driver 3 of the front-end motor of the loop correspondingly drives the front-end motor 1 of the loop to operate according to the steering and speed parameters set by the man-machine interaction interface 6, so that the operation of filling and discharging the loop is realized. The manual working mode is usually used when the loop amount is corrected after the feeding start of the production line or the overrun accident of the loop amount occurs.
When the intelligent driver 3 of the loop pre-motor detects that the man-machine interaction interface 6 sets the control mode to be an automatic mode, the intelligent driver 3 of the loop pre-motor obtains the current rotating speed setting of the loop pre-motor 1 through real-time calculation according to the actual loop amount detected by the loop position sensor 4 and the main command motor speed of the production line fed back by the main command motor speed feedback output end of the main command motor driver 2, correspondingly drives the loop pre-motor 1 to operate, automatically performs the charging and discharging operation, and enables the loop amount to reach the set value and adjusts to realize synchronous operation of the loop; the speed of the synchronous operation adjusting speed can be correspondingly adjusted by the parameters set by the man-machine interaction interface 6.
In the running process of the system, the intelligent driver 3 of the loop pre-motor monitors signals of the loop amount overrun feedback sensor group 5 in real time, once the loop amount overrun feedback sensor group 5 sends out a loop amount overcharge or loop amount overdischarge fault signal, the intelligent driver 3 of the loop pre-motor sends out an audible and visual alarm to a man-machine interaction interface, once the loop amount overrun feedback sensor group 5 sends out a loop amount overcharge and stopping and loop amount overdischarge stopping fault signal, the intelligent driver 3 of the loop pre-motor sends out a stopping instruction to the main command motor driver 2, the main command motor is stopped, and the safety of equipment is ensured.
As a preferred mode, the control system of the embodiment further comprises an upper production line main control computer 7, the intelligent loop pre-motor driver 3 is provided with a communication interface, the intelligent loop pre-motor driver 3 is in information interaction with the production line main control computer 7 through the communication interface, and the interaction information comprises a command of a man-machine interaction interface 6, system running state information and alarm information, so that control and control separation of loop transmission control is realized, and the operability and automation degree of the whole system are further improved.
The counterweight loop control system of the embodiment is used for a counterweight loop automatic charging and discharging loop and a synchronous operation control method, and comprises the following steps:
(1) the man-machine interaction interface 6 sends an automatic mode instruction to the intelligent driver 3 of the loop front-end motor;
(2) the man-machine interaction interface 6 enables the loop pre-motor 1 to run opposite to a production line main command motor driven by the main command motor driver 2 by selectively setting the forward rotation or the reverse rotation of the loop pre-motor 1;
(3) the intelligent driver 3 of the loop prepositive motor receives the detection signal sent by the loop position sensor 4 in real timeV offset Master motor operation speed fed back by master motor driver 2V 0 ；
(4) The intelligent driver 3 of the loop pre-motor adopts the method (1) to calculate the rotation speed of the loop pre-motor 1V 1 Is set at a given value of:
V 1 =K a (V 0 +K b K c (V offset -U ref / 2 + U 0 ) ) （1）
wherein,U ref the reference voltage which is the output signal of the loop position sensor 4 is the inherent parameter of the system;U 0 for regulating the amount of the loop in steady stateU ref / 2 + U 0 ) The value is regulated on the production lineThe test time optimization determination can be set in the parameter set of the intelligent driver 3 of the loop front motor; coefficients ofK c Is the ratio of the rotating speed amplitude of the loop front motor 1 to the feedback signal amplitude of the loop position sensor 4 (for example, if the speed range of the loop front motor is 0-1500 r/min and the loop position deviation signal range is + -5V, thenK c The value of 1500/5=300), the sleeve quantity deviation can be converted into the increment of the transmission speed; coefficients ofK b For adjusting the speed of charging and discharging the sleeve, increaseK b The loop can be quickly returned to the set loop amount,K b K c the value is optimized and determined during production line debugging, and can be set in a parameter set of the intelligent driver 3 of the loop front-end motor; coefficients ofK a The transmission ratio between the main motor and the loop front motor 1 of the production line is an inherent parameter of the system and can be set in a parameter group of the intelligent driver 3 of the loop front motor;
(5) the intelligent driver 3 of the looper front motor obtains the rotation speed according to the calculationV 1 Is controlled by regulating the output control loop motor 1 according to the rotation speedV 1 Is rotated by a given value; meanwhile, the intelligent driver 3 of the loop prepositive motor judges whether the current loop reaches the set loop amount, if not, the step (3) is returned; if yes, the intelligent driver 3 of the looper pre-motor controls the looper pre-motor 1 to rotate according to the current rotation speedV 1 Is rotated by a given value of (a), at the moment, dynamic and static performance indexes of speed control of the loop front motor 1 can meet the requirements of loop filling, loop discharging and synchronous operation on control precision and stability.
According to the counterweight type loop control system, the loop front motor intelligent driver 3 is used as a main control device, and the manual/automatic charging and discharging control and the synchronous operation control are directly realized by utilizing software and hardware resources of the loop front motor intelligent driver 3, so that the cost of the control system is remarkably reduced; because the loop pre-motor 1 is arranged near the loop, the control and acquisition signals can be closely connected into the loop pre-motor intelligent driver 3, the complexity of wiring is reduced, and the equipment maintenance is convenient.
The above embodiments are illustrative of the specific embodiments of the present invention, and not restrictive, and various changes and modifications may be made by those skilled in the relevant art without departing from the spirit and scope of the invention, and all such equivalent technical solutions are intended to be included in the scope of the invention.
Claims (5)
1. A counterweight type loop automatic charging and discharging sleeve and a synchronous operation control method are characterized in that: the method is implemented by a counterweight type loop control system, and the counterweight type loop control system comprises a loop front motor, a main command motor driver for driving a main command motor of a production line, a loop front motor intelligent driver for driving the loop front motor to operate, a loop position sensor for detecting a loop amount signal, a loop amount overrun sensor group for monitoring the over-charge and over-discharge of the loop amount, and a man-machine interaction interface for controlling the loop front motor through the loop front motor intelligent driver and displaying a current operation state and an audible and visual alarm signal;
the master motor driver is provided with a master motor speed feedback output end and a master motor stopping signal input end; the intelligent driver of the looper prepositive motor is provided with a signal interface board, the signal interface board is provided with at least 12 signal input/output interfaces; the sleeve amount overrun sensor group comprises a sleeve amount overcharge parking sensor, a sleeve amount overcharge alarm sensor, a sleeve amount overdischarge alarm sensor and a sleeve amount overdischarge parking sensor; the man-machine interaction interface is provided with a manual/automatic mode signal output end, a motor forward rotation/reverse rotation signal output end, a inching/rotation speed signal output end, an operation state signal input end and an audible and visual alarm signal input end;
the master electricity speed feedback output end and the master electricity stopping signal input end of the master electricity motor driver are respectively and electrically connected with 1 signal input interface and 1 signal output interface which are respectively arranged on the signal interface board of the intelligent loop motor driver; the signal output ends of the 4 sensors of the loop position sensor and the loop amount overrun sensor group are respectively and electrically connected with corresponding signal input interfaces on a signal interface board of the intelligent driver of the loop front motor; the manual/automatic mode signal output end of the man-machine interaction interface, the forward/reverse rotation signal output end of the motor and the inching/rotating speed signal output end are respectively and electrically connected with corresponding signal input interfaces on a signal interface board of the intelligent driver of the loop front motor; the operation state signal input end and the audible and visual alarm signal input end of the man-machine interaction interface are respectively and electrically connected with corresponding signal output interfaces on a signal interface board of the intelligent driver of the loop front-end motor;
the control method comprises the following steps:
(1) the man-machine interaction interface sends an automatic mode instruction to the intelligent driver of the loop front motor;
(2) the man-machine interaction interface enables the loop front motor to run opposite to the production line main command motor by selectively setting the forward rotation or the reverse rotation of the loop front motor;
(3) the intelligent driver of the loop prepositive motor receives the detection signal sent by the loop position sensor in real timeV offset Master motor operation speed fed back by master motor driverV 0 ；
(4) The intelligent driver of the loop front motor adopts the method (1) to calculate the rotating speed of the loop front motorV 1 Is set at a given value of:
V 1 =K a (V 0 +K b K c (V offset -U ref / 2 + U 0 ) ) （1）
wherein,U ref a reference voltage for the loop position sensor output signal,U 0 for regulating the amount of the loop in steady stateU ref / 2 + U 0 ) The value is optimally determined during production line debugging and is set in a parameter set of the intelligent driver of the loop front-end motor; coefficients ofK c The ratio of the rotating speed amplitude of the loop front motor to the feedback signal amplitude of the loop position sensor; coefficients ofK b Is used for adjusting the speed of sleeve filling and sleeve discharging,K b K c the value is optimally determined during production line debugging and is set in a parameter set of the intelligent driver of the loop front-end motor; coefficients ofK a For the transmission ratio between the main motor and the looper front motor of the production line, the parameter set of the intelligent driver of the loop front motor is set;
(5) the intelligent driver of the looper front motor obtains the rotation speed according to calculationV 1 Is set at a given value of (a), regulating output controls the front motor of the loop according to the rotation speedV 1 Is rotated by a given value; meanwhile, the intelligent driver of the loop prepositive motor judges whether the current loop reaches the set loop amount, if not, the step (3) is returned; if yes, the intelligent driver of the loop pre-motor controls the loop pre-motor to rotate according to the current rotation speedV 1 Is rotated by a given value of (a).
2. The automatic charging and discharging sleeve of counterweight type loop and the control method for synchronous operation according to claim 1, characterized in that: the intelligent driver of the loop front motor is a frequency converter or a servo controller with settable parameters.
3. The automatic charging and discharging sleeve of counterweight type loop and the control method for synchronous operation according to claim 1, characterized in that: the loop position sensor is arranged on an idler roller which is provided with a counterweight loop and rotates along with the idler roller so as to output a corresponding loop amount signal.
4. The automatic charging and discharging sleeve of counterweight type loop and the control method for synchronous operation according to claim 1, characterized in that: the 4 sensors of the sleeve quantity overrun sensor group are arranged on the counterweight type loop.
5. The automatic charging and discharging sleeve of counterweight loop and the control method for synchronous operation according to any one of claims 1-4, characterized in that: the control system also comprises an upper production line main control computer, the intelligent loop motor driver is provided with a communication interface, and the intelligent loop motor driver is in information interaction with the production line main control computer through the communication interface.
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