CN109613828B - Intelligent vermicelli sorting system - Google Patents
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- CN109613828B CN109613828B CN201910078367.8A CN201910078367A CN109613828B CN 109613828 B CN109613828 B CN 109613828B CN 201910078367 A CN201910078367 A CN 201910078367A CN 109613828 B CN109613828 B CN 109613828B
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Abstract
The invention discloses an intelligent vermicelli sorting system, and belongs to the field of automatic sorting systems; the intelligent vermicelli sorting system based on the PLC takes washed vermicelli as a sorting system of sorting objects, and the control of the weight of the grasped vermicelli is realized by fuzzy control; the automatic control of procedure links such as vermicelli grabbing, weighing and forming is realized, and the product quality and the production efficiency are remarkably improved. The mechanical system consists of four parts, namely a mechanical arm, a guide rail, a top cover frame and a rotary table. The intelligent vermicelli sorting system is designed by starting with the physical characteristics of vermicelli, grabbing the vermicelli by adopting mechanical claws according to the characteristics of irregular shape and intertwining of the vermicelli, collecting weight information of the vermicelli by a weighing sensor, converting the weight information into an electric signal by a weight transmitter, and transmitting the electric signal to a controller; when the grabbing weight of the vermicelli is higher than the design requirement, the mechanical claws shake, and the excessive vermicelli is shaken off; when the grabbing weight of the vermicelli is lower than the design requirement, the mechanical claws grab again.
Description
Technical Field
The invention belongs to the field of automatic sorting systems, and particularly relates to an intelligent vermicelli sorting system.
Background
Vermicelli is used as traditional food for Chinese nationality and is widely visible in daily life of people. At present, the production process of the vermicelli still adopts a traditional production mode. The production mode is completed manually in the process of grabbing, weighing and shaping the vermicelli, so that the traditional production of the vermicelli has the following defects: the food safety is difficult to control, the production efficiency is low, and the labor cost is too high. Although this production method has been in the food processing industry for a long time, with the development of commercial economy, the improvement of working efficiency and living standard of people, the diet concept of healthy life has been deep, and this production method is finally eliminated by the industry. Meanwhile, it is important to design a set of automation system which can change the production mode of vermicelli, replace manpower with machinery, ensure food safety, improve product quality and production efficiency and reduce labor cost.
The main process of vermicelli production comprises: raw materials and auxiliary materials are added with water and stirred, slurry is distributed, self-cooked silk extrusion, continuous pre-aging, freezing, thawing, powder washing, water filtering and conveying, manual quantitative box filling, continuous automatic drying, storage, packaging and finished product preparation. The specific operation of the vermicelli in the thawing link, the vermicelli washing link and the filtered water conveying link is as follows: and (5) placing the thawed powder blocks into a powder washer. The turbine in the powder washer rotates to drive the water and the powder blocks to stir, so that the adhered vermicelli are mutually dispersed. And then the scattered vermicelli and water are discharged into a water filtering conveyor to filter out the water on the surface of the vermicelli. The processing of the three links ensures that the interior of the vermicelli is filled with water, so that the physical characteristics of the vermicelli are changed, the surface of the vermicelli becomes smooth, and the texture of the vermicelli becomes soft and difficult to grasp. Meanwhile, as the turbine rotates to drive the water and the powder blocks to form stirring, the powder blocks with regular shapes are scattered, and the vermicelli are mutually wound together.
The design goal of the vermicelli sorting machine system is to replace the manual processes of sorting, weighing and shaping of the defrosted vermicelli by a machine, so that the safety of food is ensured, the quality and production efficiency of the product are improved, and the labor cost is reduced. The function to be realized by the design system is quantitative grabbing and automatic shaping of the vermicelli. When the mechanical claws take the vermicelli, the weight of the vermicelli which is usually grabbed by the mechanical claws is larger than the required weight of the vermicelli because the vermicelli is mutually intertwined. The mechanical claws are rapidly opened and closed to generate shaking, so that the excessive vermicelli is shaken off. Therefore, how to determine the shake time of the gripper according to the error of the vermicelli weight is a key problem.
Disclosure of Invention
In order to solve the technical problems, the invention provides a fuzzy control method, and designs a fuzzy controller, wherein the input of the controller is the error of the weight of the vermicelli, and the output is the shaking time of a mechanical hand, namely, the shaking time of a mechanical claw is determined according to the error change of the weight of the grabbing vermicelli by utilizing a fuzzy reasoning rule, so that the accuracy of the mechanical claw on the grabbing weight of the vermicelli is improved. The invention provides a vermicelli sorting system which consists of a mechanical structure part, a computer, a PLC, a motor and the like and is subjected to fuzzy control. The vermicelli sorting system is reasonable in structure and complete in function.
An intelligent vermicelli sorting system comprises a mechanical structure part, a computer, a Smart SR30PLC, an AE04 expansion module, a weighing sensor, a start button, a stop button, a limit switch, a mechanical claw, a direct current motor, a relay and a lamplight alarm part.
Further, the components of the mechanical structure part are respectively made into assembly components; the two guide rails are fixed through aluminum profiles to form a parallel position relationship, and sliding blocks on the guide rails are fixed with the bottom of the mechanical arm through screws; the main body framework of the mechanical arm is a cube formed by mutually fixing 12 aluminum profiles, the arm of the mechanical arm is a rectangle formed by mutually fixing 4 aluminum profiles, the position of the arm is parallel to the upper bottom and the lower bottom of the cube, the tail end of the rectangle structure is provided with a sliding block, the sliding block moves up and down through a sliding rod, and the two ends of the sliding rod are fixed at the upper end and the lower end of the main body framework of the mechanical arm; the motor is fixed to the bottom of the main body framework of the mechanical arm, and drives the mechanical arm to move up and down through the conveyor belt; the front end of an arm of the mechanical arm is connected with the top end of a weighing sensor, and the bottom of the weighing sensor is connected with a mechanical claw; the vermicelli container is arranged under the mechanical claw and is in the same horizontal plane with the guide rail, and the difference between the internal connection relation of the top cover frame and the internal connection relation of the mechanical arm is that the front end of the arm of the top cover frame is connected with the top cover; the top cover is arranged at the tail part of the guide rail, and the top cover and the guide rail are connected through an angle brace and an aluminum profile; the turntable is positioned at the tail part of the guide rail, the position of the turntable is parallel to the top cover frame, and the turntable and the top cover frame are respectively connected at two sides of the tail part of the guide rail; the turntable is connected with the guide rail by an angle code, the aluminum profile is connected with the bottom of the turntable, the motor is arranged on the aluminum profile, and the motor directly drives the turntable to rotate through a gear.
Further, the control system is composed of an upper computer system and a lower computer system, the upper computer system and the lower computer system are communicated by adopting an OPC protocol, the upper computer system is a computer provided with a Windows operating system, and the lower computer system is composed of a Siemens Smart-SR30PLC, an AE04 expansion module, a weighing sensor, a relay, a direct-current motor, a limit switch and a start-stop button.
The upper computer interface controls the operation of the system through starting and stopping buttons;
the lower computer adopts Siemens Smart-SR30PLC as a core controller, and realizes the action of mechanical claws by controlling the attraction of a relay, and the mechanical arm moves in a two-dimensional space and forms vermicelli; the AE04 expansion module converts the signals measured by the weighing sensor into voltage signals of 0-10V and sends the voltage signals to the PLC, so that the PLC obtains the weight of the grabbing vermicelli.
Further, the hardware design comprises a controller, an expansion module, a weighing sensor, a transmitter of the weighing sensor, a motor (4) and auxiliary hardware.
Further, the controller and the expansion module are designed as follows:
the control system needs to use 8 paths of digital quantity input signals, including 1 path of start and stop buttons, and 1 path of input of each limit switch is 6 paths. The digital quantity output circuit comprises 8 paths, namely 6 paths for controlling the running direction of 3 direct current motors, and 1 path for controlling the opening and closing of the mechanical claw and the output of 1 path of running indicator lamps; analog quantity input 1 path, analog quantity output 1 path; the controller is powered by a 220V alternating current power supply, and Siemens company S7-200Smart SR30PLC with 18 input/12 output; the expansion module selects an EM AE04 expansion module with 4 paths of analog quantity input and 24V direct current power supply.
Further, the PLC controls the mechanical claws to grasp the weight information of the vermicelli all from the weighing sensor.
The weighing sensor is a resistance strain sensor, and according to the specific requirements of the system, a clam port sensing instrument limited company DYLY-106 weighing sensor is selected, the power supply voltage of the sensor is 5-15 VDC, and the output signal of the sensor is 0-10V standard signal; the matched transmitter of the weighing sensor selects a DY510 type weight transmitter of the clam port sensing instrument limited company; the DY510 transmitter converts the mechanical quantity into standard current and voltage signals to be output, and the voltage signals can be switched to 0-5V/0-10V; can be directly connected with automatic control equipment PLC; the system has the functions of external zero setting and external gain adjustment of standard signals, input over-protection and output short-circuit protection.
Further, the system adopts a direct current motor as a controlled object of the system; the direct current motor is an XD-37GB555 direct current gear motor, and the rotating speed is 100r/min.
Further, the relay type number in the auxiliary hardware design is MY4N-J; the branching structure of the gripper is increased by 3D printing technology.
Further, the software design includes the following program portions
(1) Mechanical claw shaking program
The shaking of the mechanical claw is realized by controlling the relay to be rapidly attracted and disconnected in a short time, and the shaking time of the mechanical claw is the output value of the fuzzy controller;
(2) Vermicelli weight acquisition program
For the analog input module, the analog signal of 0-10V corresponds to data of 0-27648, so that the obtained digital quantity is required to be converted into actual weight to be convenient to read and calculate;
s7-200Smart PLC does not allow shaping data to be directly converted into floating point number, so that the value of analog quantity channel AIW16 is converted into double word type through I_DI instruction and stored in a register; the value in the register is converted into a floating point number through DI_R, so that the precision of the data is improved; dividing the register by 17648 to obtain the percentage of the input value in the whole input range; then multiplied by 1000 to give the actual value of the weight in grams (g).
(3) Fuzzy control program for mechanical claw shaking time
A fuzzy control method is adopted; the input of the fuzzy controller is the error of the weight of the vermicelli, the output is the shaking time of the mechanical hand, and the shaking time of the mechanical claw is determined according to the error change of the weight of the grabbing vermicelli by utilizing a fuzzy reasoning rule, so that the accuracy of the mechanical claw on the grabbing weight of the vermicelli is improved; .
(4) Upper computer design
The upper computer interface uses WinCC for configuration, OPC is used for communication protocol and S7-200 PC Access SMART is used for establishing communication between WinCC and S7-200 SMART; the upper computer interface is divided into an automatic monitoring part and a manual operation part, the automatic monitoring part can control the automatic operation of the system through a start button and a stop button, when the system operates, the screen can display the weight of the vermicelli in real time, and meanwhile, the required weight of the vermicelli can be preset; the manual operation is applied in the system detection and maintenance stage, and the movement of each mechanical arm and the suction of the mechanical claw are controlled through the button; meanwhile, the method has a history data recording function, and can record the weight of each vermicelli in a table and draw a trend chart.
Advantages and beneficial effects of the invention
1) The vermicelli sorting system of this design can replace the manual work to accomplish vermicelli letter sorting, weigh, design process under the circumstances that does not change vermicelli length. Ensuring food safety, improving production efficiency of products and reducing labor cost;
2) The fuzzy control is applied to the vermicelli sorting system, the advantage that the fuzzy control does not need to establish an accurate mathematical model of a controlled object is utilized, and the shaking time of the mechanical claw is controlled by grabbing the deviation of the weight of the vermicelli, so that the production efficiency of the vermicelli is improved;
3) The system designed in the method can be suitable for the production site with complex environment, and has the advantages of simple structure, stable operation and low economic cost.
Drawings
FIG. 1 is an overall block diagram of a vermicelli sorting system;
FIG. 2 is a functional diagram of a vermicelli sorting system;
FIG. 3 is an overall workflow diagram of a vermicelli sorting system;
FIG. 4 is a 3D structure diagram of a vermicelli grabbing and quantifying structure;
FIG. 5 is a 3D structure diagram of a vermicelli shaping structure;
FIG. 6 is an overall mechanical structure diagram of a vermicelli sorting and sizing system;
FIG. 7 is a block diagram of a control system;
FIG. 8 is a schematic diagram of the external wiring of the PLC and expansion module;
FIG. 9 is a wiring diagram of a pressure sensor and weight transmitter;
FIG. 10 is a diagram of a direct current motor forward and reverse winding;
FIG. 11 is a flow chart of gripper dithering;
FIG. 12 is a flow chart for vermicelli weight acquisition;
FIG. 13 is a flow chart of fuzzy control of the gripper dithering time;
FIG. 14 is a diagram of a monitoring interface;
FIG. 15 is a graph of vermicelli weight records and trends;
in the figure: 1 is a sliding block; 2 is a slide bar, 3 is a top cover; 4 is a motor; 5 is a turntable; 6 is a mechanical claw; 7 is a weighing sensor; 8 is a guide rail; 9 is a top cover frame; 10 is a mechanical arm; and 11 is a vermicelli container.
Detailed Description
The present invention will be described in detail below with reference to the drawings and examples for further illustration of the invention, but they should not be construed as limiting the scope of the invention.
Examples:
1. integral structural design
The vermicelli sorting system of this design mainly comprises mechanical structure part, computer, smart SR30PLC, AE04 expansion module, weighing sensor 7, start button, stop button, limit switch, gripper 6, direct current motor 4, relay and parts such as light alarm, and the following figure 1 is the whole structure diagram of vermicelli sorting system.
2. Integral functional design
The whole function of the vermicelli sorting system mainly comprises two parts of quantitative vermicelli grabbing and vermicelli forming, and the following figure 2 is a functional diagram of the vermicelli sorting system.
3. Integrated workflow
After the vermicelli sorting system is powered on, firstly, a reset program is executed, then quantitative grabbing is carried out on vermicelli, and if the weight of the vermicelli is higher than a set range, the mechanical claw 6 shakes; if the weight of the vermicelli is lower than the set range, grabbing again; if the weight of the grabbed vermicelli accords with the set range, putting the vermicelli into a formed vermicelli container 11, and rotating and forming. An overall workflow diagram of the vermicelli sorting system is shown in fig. 3 below.
4. Mechanical mechanism design
The design adopts a bottom-up assembly method, firstly, parts are assembled into parts with different functions, and then the parts are assembled into a whole in a unified way. During assembly, the vermicelli sorting and shaping system is divided into mechanical arms 10, guide rails 8, top cover frames 9, turntables 5 and the like to be manufactured into assembly parts respectively, and finally unified assembly is carried out.
The grabbing of the vermicelli is completed by a mechanical arm 10 and a guide rail 8, and the structure of the vermicelli is shown in fig. 4. When the vermicelli is grabbed and then placed in the specified vermicelli container 11, after the top cover 3 descends for a certain distance, the motor 4 of the turntable 5 is started to drive the vermicelli container 11 to rotate together at a high speed, and the top cover 3 plays a role in preventing the vermicelli from flying out of the vermicelli container 11 in the high-speed rotation. The mechanical structure mainly comprises a roof rack 9 and a turntable 5,3d modeling is shown in fig. 5. The overall mechanical structure of the system is shown in fig. 6.
5. Control system design
The vermicelli sorting system mainly comprises an upper computer system and a lower computer system, wherein the upper computer system and the lower computer system are communicated by adopting an OPC protocol, the upper computer system is a computer provided with a Windows operating system, and the lower computer system comprises a Siemens Smart-SR30PLC, an AE04 expansion module, a weighing sensor 7, a relay, a direct-current motor 4, a limit switch, a start-stop button and the like. Fig. 7 shows a control system configuration diagram.
The upper computer interface controls the operation of the system through the start and stop buttons, and when the system is in operation, the upper computer monitoring picture can display the weight of the vermicelli in real time, and meanwhile, the required weight of the vermicelli can be preset to adapt to different production requirements. The upper computer has a history data recording function, can record the weight of vermicelli at each time in a table and draw a trend chart, and is convenient for observation and equipment debugging.
The lower computer adopts Siemens Smart-SR30PLC as a core controller, and realizes the action of the mechanical claw 6 by controlling the attraction of the relay, and the mechanical arm 10 moves in two-dimensional space and forms vermicelli. The AE04 expansion module converts the signal measured by the weighing sensor 7 into a voltage signal of 0-10V and sends the voltage signal to the PLC, so that the PLC obtains the weight of the grabbing vermicelli.
6. Hardware design
(1) Design of controller and expansion module
The control system needs to use 8 paths of digital quantity input signals, including 1 path of start and stop buttons, and 1 path of input of each limit switch is 6 paths. The digital quantity output 8 paths comprise 3 running direction control 6 paths of direct current motors 4, and 1 path of digital quantity output is used for controlling the opening and closing of the mechanical claw 6 and 1 path of running indicator lamp output. The analog quantity is input into 1 path, and the analog quantity is output into 1 path. The controller is powered by 220V AC power, 18 input/12 output Siemens company S7-200Smart SR30 PLC. The expansion module selects an EM AE04 expansion module with 4 paths of analog quantity input and 24V direct current power supply. The external wiring diagram of the PLC and the expansion module is shown in FIG. 8.
(2) Load cell 7 and transmitter thereof
The load cell 7 is the primary sensor in the present system. The weight information of the PLC control mechanical claw 6 for grabbing the vermicelli comes from the weighing sensor 7, which has to have high reliability, and if the weighing sensor 7 goes wrong, the stability and the accuracy of the operation of the whole system are affected, so the selection of the weighing sensor 7 is very critical.
The load cell 7 is a resistive strain gauge sensor. According to the specific requirements of the system, a clam port sensing instrument limited company DYLY-106 type weighing sensor 7 is selected, the power supply voltage of the sensor is 5-15 VDC, and the output signal of the sensor is 0-10V standard signal. The mating transmitter of the load cell 7 is selected from the DY510 type weight transmitter of the clam port sensor instruments Co. The DY510 transmitter converts the mechanical quantity into standard current and voltage signals to be output, and the voltage signals can be switched between 0V and 5V and 0V to 10V. Can be directly connected with automatic control equipment PLC. The system has the functions of external zero setting and external gain adjustment of standard signals, input over-protection and output short-circuit protection. A wiring diagram of the pressure sensor and the weight transducer is shown in fig. 9.
(3) Selection of the electric machine 4
The development system needs more motors 4, and takes the four factors of the rotation speed, the load, the reaction speed and the economic cost of the motors 4 into consideration, and then adopts the direct current motors 4 as controlled objects of the system. The direct current motor 4 selects an XD-37GB555 type direct current gear motor 4, and the rotating speeds are respectively 100r/min and 300 r/min. The front and back patch cord diagram of the dc motor 4 is shown in fig. 10.
(4) Other hardware designs
The relay plays a non-negligible reuse in the design system, and the PLC controls the suction of the relay to further complete the starting and stopping of the motor 4 and the grabbing, shaking and other setting actions of the mechanical claw 6. The relay type number selected by the design system is MY4N-J.
In the design, the mechanical claw 6 finishes the grabbing work of the vermicelli, selects the mechanical claw 6 with simple mechanical structure and easy control according to the physical characteristics and design requirements of the vermicelli, and increases the branch structure of the mechanical claw 6 through a 3D printing technology according to the actual grabbing effect.
7 software design
(1) Gripper 6 dithering process
During the process of grabbing the vermicelli, the grabbing weight of the vermicelli is larger than the required weight, and then the excessive vermicelli needs to be removed through shaking of the mechanical claws 6. The shaking of the mechanical claw 6 is realized by controlling the relay to be rapidly switched on and off in a short time, and the shaking time of the mechanical claw 6 is the output value of the fuzzy controller. The flow of control of the shake of the gripper 6 is shown in fig. 11.
(2) Vermicelli weight acquisition program
For the analog input module, the analog signal of 0-10V corresponds to the data of 0-27648, so that the obtained digital quantity needs to be converted into the actual weight to be conveniently read and calculated. The vermicelli weight acquisition flow chart is shown in fig. 12.
S7-200Smart PLC does not allow the shaping data to be directly converted into floating point number, so the value of the analog quantity channel AIW16 is firstly converted into double word type through I_DI instruction and stored in a register. And the value in the register is converted into the floating point number through DI_R, so that the precision of the data is improved. Dividing the register by 17648 yields the input value as a percentage of the entire input range. Then multiplied by 1000 to give the actual value of the weight in grams (g).
(3) Fuzzy control program for dithering time of mechanical claw 6
Because the mechanical claw 6 grabs the weight of the vermicelli and has the characteristic of nonlinearity, and an accurate mathematical model is difficult to build, a fuzzy control method is adopted. The input of the fuzzy controller is the error of the weight of the vermicelli, the output is the shaking time of the mechanical hand, and the shaking time of the mechanical claw 6 is determined according to the error change of the weight of the grabbing vermicelli by utilizing a fuzzy reasoning rule, so that the accuracy of the mechanical claw 6 on the grabbing weight of the vermicelli is improved. The flow of the fuzzy control of the shake time of the gripper 6 is shown in fig. 13.
(4) Upper computer design
The upper computer interface of the design is configured by using WinCC, and communication protocols and S7-200 PC Access SMART are carried out by using OPC to establish communication between WinCC and S7-200 SMART. The upper computer interface is mainly divided into an automatic monitoring part and a manual operation part, the automatic monitoring part can control the automatic operation of the system through a start button and a stop button, when the system is operated, the screen can display the weight of the vermicelli in real time, and meanwhile, the required weight of the vermicelli can be preset to adapt to different production requirements. The manual operation is mainly applied in the system detection and maintenance stage, and the movement of each mechanical arm 10 and the suction of the mechanical claw 6 can be controlled by the buttons. Meanwhile, the device has a historical data recording function, can record the weight of vermicelli in each time in a table and draw a trend chart, and is convenient to observe and debug equipment. The monitoring interface in the running process of the system is shown in fig. 14, and the vermicelli weight record and trend chart are shown in fig. 15.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (8)
1. An intelligent vermicelli sorting system which is characterized in that: the intelligent weighing sensor consists of a mechanical structure part, a computer, a Smart SR30PLC, an AE04 expansion module, a weighing sensor (7), a start button, a stop button, a limit switch, a mechanical claw (6), a direct current motor, a relay and a lamplight alarm part;
the parts of the mechanical structure part are respectively manufactured into assembly parts; the two guide rails (8) are fixed through aluminum profiles to form a parallel position relationship, and a sliding block (1) at the upper part of each guide rail (8) is fixed with the bottom of the mechanical arm (10) through screws; the main body framework of the mechanical arm (10) is a cube formed by mutually fixing 12 aluminum profiles, the arm of the mechanical arm (10) is a rectangle formed by mutually fixing 4 aluminum profiles, the position of the arm is parallel to the upper bottom and the lower bottom of the cube, the tail end of the rectangle is provided with a sliding block (1), the sliding block (1) moves up and down through a sliding rod (2), and the two ends of the sliding rod (2) are fixed at the upper end and the lower end of the main body framework of the mechanical arm (10); the direct current motor (4) is fixed to the bottom of the main body framework of the mechanical arm (10), and the direct current motor (4) drives the mechanical arm (10) to move up and down through a conveyor belt; the front end of an arm of the mechanical arm (10) is connected with the top end of a weighing sensor (7), and the bottom of the weighing sensor (7) is connected with a mechanical claw (6); the vermicelli container (11) is arranged at the position right below the mechanical claw (6) and is in the same horizontal plane with the guide rail (8), and the difference between the internal connection relation of the top cover frame (9) and the internal connection relation of the mechanical arm (10) is that the front end of the arm of the top cover frame (9) is connected with the top cover (3); the top cover frame (9) is arranged at the tail part of the guide rail (8), and the top cover frame and the guide rail are connected by corner brackets and aluminum profiles; the turntable (5) is positioned at the tail part of the guide rail (8) and is parallel to the top cover frame (9), and the turntable (5) and the top cover frame (9) are respectively connected at two sides of the tail part of the guide rail (8); the turntable (5) is connected with the guide rail (8) through an angle code, the bottom of the turntable (5) is composed of aluminum profiles, the direct current motor (4) is arranged on the aluminum profiles, and the direct current motor (4) directly drives the turntable (5) to rotate through a gear.
2. The intelligent fan-out sorting system of claim 1, wherein: the control system consists of an upper computer system and a lower computer system, wherein the upper computer system and the lower computer system are communicated by adopting an OPC protocol, the upper computer system is a computer provided with a Windows operating system, and the lower computer system consists of a Siemens Smart-SR30PLC, an AE04 expansion module, a weighing sensor (7), a relay, a direct-current motor (4), a limit switch and a start-stop button;
the upper computer interface controls the operation of the system through starting and stopping buttons;
the lower computer adopts Siemens Smart-SR30PLC as a core controller, and realizes the action of the mechanical claw (6) by controlling the attraction of the relay, and the mechanical arm (10) moves in two-dimensional space and forms vermicelli; the AE04 expansion module converts the signal measured by the weighing sensor (7) into a voltage signal of 0-10V and feeds the voltage signal into the PLC, so that the PLC obtains the weight of the grabbing vermicelli.
3. The intelligent fan-out sorting system of claim 1, wherein: the hardware design comprises a controller, an expansion module, a weighing sensor (7), a transmitter thereof, a direct current motor (4) and auxiliary hardware.
4. The intelligent fan-out sorting system of claim 3, wherein: the design of the controller and the expansion module is as follows:
the control system needs to use 8 paths of digital quantity input signals, including 1 path of start and stop buttons, and each limit switch inputs 1 path and 6 paths;
the digital quantity output circuit comprises 8 paths, namely 6 paths for controlling the running direction of 3 direct current motors (4), and 1 path for controlling the opening and closing of the mechanical claw (6) and the output of 1 path of running indicator lamps; analog quantity input 1 path, analog quantity output 1 path; the controller is powered by a 220V alternating current power supply, and Siemens company S7-200Smart SR30PLC with 18 input/12 output; the expansion module selects an EM AE04 expansion module with 4 paths of analog quantity input and 24V direct current power supply.
5. The intelligent fan-out sorting system of claim 3, wherein: the PLC controls the mechanical claw (6) to grasp the weight information of the vermicelli and all the weight information come from the weighing sensor (7);
the weighing sensor (7) is a resistance strain sensor, and according to the specific requirements of the system, the clam port sensing instrument limited company DYLY-106 weighing sensor (7) is selected, the power supply voltage of the sensor is 5-15 VDC, and the output signal is 0-10V standard signal; the matched transmitter of the weighing sensor (7) is a DY510 type weight transmitter of the clam port sensing instrument limited company; the DY510 transmitter converts the mechanical quantity into standard current and voltage signals to be output, and the voltage signals can be switched to 0-5V/0-10V; can be directly connected with automatic control equipment PLC; the system has the functions of external zero setting and external gain adjustment of standard signals, input over-protection and output short-circuit protection.
6. The intelligent fan-out sorting system of claim 3, wherein: the system adopts a direct current motor (4) as a controlled object of the system; the direct current motor (4) selects an XD-37GB555 type direct current gear motor (4) with the rotating speed of 100r/min.
7. The intelligent fan-out sorting system of claim 3, wherein: the relay type number in the auxiliary hardware design is MY4N-J; the branching structure of the mechanical gripper (6) is increased through the 3D printing technology.
8. The intelligent fan-out sorting system of claim 1, wherein: the software design includes the following program parts
1) A gripper (6) dithering program;
the shaking of the mechanical claw (6) is realized by controlling the relay to be rapidly attracted and disconnected in a short time, and the shaking time of the mechanical claw (6) is the output value of the fuzzy controller;
2) A vermicelli weight obtaining program;
for the analog input module, the analog signal of 0-10V corresponds to data of 0-27648, so that the obtained digital quantity is required to be converted into actual weight to be convenient to read and calculate;
s7-200Smart PLC does not allow shaping data to be directly converted into floating point number, so that the value of analog quantity channel AIW16 is converted into double word type through I_DI instruction and stored in a register; the value in the register is converted into a floating point number through DI_R, so that the precision of the data is improved; dividing the register by 17648 to obtain the percentage of the input value in the whole input range; then multiplying by 1000 to obtain an actual value of weight in grams (g);
3) A fuzzy control program for the shaking time of the mechanical claw (6);
a fuzzy control method is adopted; the input of the fuzzy controller is the error of the weight of the vermicelli, the output is the shaking time of the mechanical hand, and the shaking time of the mechanical claw (6) is determined according to the error change of the weight of the grabbing vermicelli by utilizing a fuzzy reasoning rule, so that the accuracy of the mechanical claw (6) on the grabbing weight of the vermicelli is improved;
4) Upper computer design
The upper computer interface uses WinCC for configuration, OPC is used for communication protocol and S7-200 PC Access SMART is used for establishing communication between WinCC and S7-200 SMART; the upper computer interface is divided into an automatic monitoring part and a manual operation part, the automatic monitoring part can control the automatic operation of the system through a start button and a stop button, when the system operates, the screen can display the weight of the vermicelli in real time, and meanwhile, the required weight of the vermicelli can be preset; the manual operation is applied in the system detection and maintenance stage, and the movement of each mechanical arm (10) and the suction of the mechanical claw (6) are controlled through the button; meanwhile, the method has a history data recording function, the weight of each vermicelli is recorded in a table, and a trend chart is drawn.
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