CN114019892B - Pneumatic flexible device control system and method based on PLC - Google Patents
Pneumatic flexible device control system and method based on PLC Download PDFInfo
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- CN114019892B CN114019892B CN202111233509.7A CN202111233509A CN114019892B CN 114019892 B CN114019892 B CN 114019892B CN 202111233509 A CN202111233509 A CN 202111233509A CN 114019892 B CN114019892 B CN 114019892B
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- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000003754 machining Methods 0.000 claims abstract description 36
- 238000003825 pressing Methods 0.000 claims abstract description 32
- 238000006073 displacement reaction Methods 0.000 claims abstract description 24
- 230000005484 gravity Effects 0.000 claims abstract description 21
- 230000006835 compression Effects 0.000 claims description 11
- 238000007906 compression Methods 0.000 claims description 11
- 238000005303 weighing Methods 0.000 claims description 9
- 230000001133 acceleration Effects 0.000 claims description 4
- 230000002457 bidirectional effect Effects 0.000 claims description 2
- 238000005498 polishing Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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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
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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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
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/11—Plc I-O input output
- G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor
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Abstract
The invention relates to a pneumatic flexible device control system and a method based on PLC, the system comprises a cylinder, a piston rod of the cylinder is connected with an end tool through a guide rail, the system also comprises a pressure sensor for measuring the pressing force between the end tool and a processing surface, a displacement sensor for measuring the displacement of the guide rail, a pose sensor for measuring the pose of the piston rod of the cylinder and a PLC controller for controlling a control valve of the cylinder; the guide rail and the end tool are used as loads, the loads are automatically weighed before the end tool acts on the machining surface, and after the end tool acts on the machining surface, the PLC collects the actual pressing force between the end tool and the machining surface, the displacement of the guide rail and the pose of a cylinder piston rod in real time, compensates the output force of the cylinder based on the load gravity, and accurately controls the pressing force between the end tool and the machining surface to keep constant. Compared with the prior art, the pneumatic flexible device has high output force control precision and high reliability.
Description
Technical Field
The invention relates to the technical field of pneumatic compliance control, in particular to a pneumatic compliance device control system and method based on a PLC.
Background
At present, the finishing operations such as grinding and polishing of a plurality of parts in industry mainly depend on skilled workers to manually grind or use a grinding machine to process, but the processing quality of the workers is uneven, the processing efficiency is low, the working environment is hard, the requirements on the proficiency of the workers are high, and the processing level cannot be ensured; although the grinding machine has stable processing quality and high efficiency, the grinding machine can only polish one type of parts and is greatly limited, so that a processing device with enough flexibility and accuracy is necessary. The positioning accuracy of the current robot is far higher than that of a common machine tool, so that the adoption of robot processing is a good alternative. In order to obtain more uniform surface quality during the fine machining of parts, the constant polishing force must be ensured on the premise of ensuring the stable rotation speed and feeding speed of the polishing tool, so that the polishing force needs to be controlled by adopting a pneumatic flexible device.
Most of polishing force control systems in the market are designed by circuit control, the control mode is complex, and faults are easy to occur when a circuit board is impacted or subjected to other physical actions due to a compliant device.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a pneumatic flexible device control system and method based on a PLC.
The aim of the invention can be achieved by the following technical scheme:
The pneumatic flexible device control system based on the PLC comprises a cylinder with bidirectional output force, wherein a piston rod of the cylinder is connected with an end tool through a guide rail, the end tool acts on a processing surface, and the system further comprises a pressure sensor for measuring the pressing force on the end tool and the processing surface, a displacement sensor for measuring the displacement of the guide rail, a pose sensor for measuring the pose of the piston rod of the cylinder and a PLC controller for controlling a control valve of the cylinder;
And the PLC collects the actual compression force, guide rail displacement and cylinder rod pose on the end tool and the machining surface in real time after the end tool acts on the machining surface, compensates the output force of the cylinder based on the load gravity and accurately controls the compression force on the end tool and the machining surface to keep constant.
Preferably, the pose sensor comprises an acceleration sensor for measuring the angle between the cylinder piston rod and the plumb line.
A control method of a pneumatic compliance device based on a PLC, the control system of the method, the method comprising:
taking the guide rail and the tail end tool as loads, adjusting load positions, starting the air cylinder and gradually increasing the output force of the air cylinder until the displacement sensor outputs displacement, simultaneously recording the angle between the current air cylinder piston rod and the plumb line and the output force of the air cylinder, and calculating the weight of the load based on the output force of the air cylinder and the angle between the current air cylinder piston rod and the plumb line;
The method comprises the steps that an end tool acts on a machining surface, the actual compression force between the end tool and the machining surface, the displacement of a guide rail and the pose of a cylinder rod are collected in real time, the set compression force between the end tool and the machining surface is compared with the actual compression force, and the output force of a cylinder is compensated once based on load gravity to obtain a first compensation given value of the output force of the cylinder;
Based on the actual output force of the cylinder and a given value of the output force of the cylinder in the previous control period, performing secondary compensation on the output force of the cylinder by adopting an incremental PID control algorithm to obtain a second compensation given value of the output force of the cylinder;
And controlling the cylinder to work based on the second compensation given value of the output force of the cylinder.
Preferably, the load position is adjusted to: the angle between the output force direction of the air cylinder and the gravity direction of the load is 0-45 degrees.
Preferably, the cylinder output force is increased stepwise in the order of 0.1N when the load is automatically weighed.
Preferably, the specific way of compensating the cylinder output force once based on the load gravity comprises the following steps:
S1, acquiring an angle between a cylinder piston rod and a plumb line, and calculating acting force F p of the gravity applied to the cylinder piston rod by the load according to the load gravity, wherein if the direction F p points to the direction of a machining surface, F p is more than 0, and otherwise F p is less than 0;
s2, acquiring actual pressing force Fr of the end tool and the processing surface in real time, and acquiring set pressing force Fs of the end tool and the processing surface at the same time;
s3, if F p is more than 0, executing a step S4, otherwise executing a step S5;
S4, if Fr is larger than Fs, F n+1,1＝Fn-|Fp -Fr-Fs is larger than F2, otherwise F n+1,1＝Fn-|Fp -Fr-Fs is larger than F2, wherein F n is a given value of output force of the cylinder at time n, and F n+1,1 is a first compensation given value of output force of the cylinder at time n+1;
S5, if Fr is larger than Fs, F n+1,1＝Fn+|Fp -Fr-Fs is larger than F2, otherwise F n+1,1＝Fn+|Fp -Fr-Fs is larger than F2, wherein F n is a given value of output force of the cylinder at time n, and F n+1,1 is a first compensation given value of output force of the cylinder at time n+1.
Preferably, the specific mode of adopting the incremental PID control algorithm to secondarily compensate the output force of the cylinder is as follows:
acquiring a cylinder output force secondary compensation value F Δ based on an incremental PID control algorithm;
calculating a second compensation given value of the output force of the cylinder: f n+1,2＝Fn+1,1+FΔ.
Preferably, in step S1, F p is calculated by the following formula: f p＝Fg·cosθ,Fg is the load weight, θ is the angle of the cylinder rod with the plumb line.
Preferably, F Δ is obtained by the formula:
FΔ＝Kp(F(n)-F(n-1))+KiF(n)+Kd(F(n)-2F(n-1)+F(n-2))
F(n)＝FS(n)-Fr(n)
F(n-1)＝FS(n-1)-Fr(n-1)
F(n-2)＝FS(n-2)-Fr(n-2)
Wherein, F S(n)、FS(n-1)、FS (n-2) respectively represents the set pressing forces on the end tool and the machining surface at the time of n, the time of n-1 and the time of n-2, F r(n)、Fr(n-1)、Fr (n-2) respectively represents the actual pressing forces on the end tool and the machining surface at the time of n, the time of n-1 and the time of n-2, when n=0, F (n-1) =f (n-2) =0, and k p、Ki、Kd is a PID parameter.
Preferably, K p、Ki、Kd takes the following value:
when the value range of the set pressing force Fs between the end tool and the processing surface is (0N, 100N), K p＝3.5,Ki＝0.02,Kd =0;
when the value range of the set pressing force Fs between the end tool and the processing surface is (100N, 200N), K p＝2.5,Ki＝0.02,Kd =0;
when the set pressing force Fs between the end tool and the working surface is in the range of (200 n,400 n), K p＝1.5,Ki＝0.02,Kd =0.
Compared with the prior art, the invention has the following advantages:
(1) The PLC is arranged outside the pneumatic flexible device, so that the sensor signal can be received, the control system fault caused by the interference of the pneumatic flexible device in the motion process can be avoided, the stability and the maintainability of the PLC are fully utilized, and the reliability of the pneumatic flexible device is greatly improved;
(2) The invention adopts a scheme which is different from the conventional integrated circuit control, but adopts PLC as distributed control, thereby reducing the volume of the device and avoiding the mechanical impact of the control system in the use process of the device;
(3) The invention adopts the functions of automatic weighing and gravity compensation, introduces an incremental PID control algorithm, and improves the accuracy of the output force control of the pneumatic flexible device.
Drawings
FIG. 1 is a block diagram of a pneumatic compliance device control system based on a PLC of the present invention;
FIG. 2 is a schematic diagram of a cylinder with bi-directional output force according to the present invention;
FIG. 3 is a flow chart of the present invention for automatic weighing of a load;
FIG. 4 is a schematic diagram of the invention for automatic weighing of a load;
fig. 5 is a flow chart of the present invention for cylinder accurate force control.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples. Note that the following description of the embodiments is merely an example, and the present invention is not intended to be limited to the applications and uses thereof, and is not intended to be limited to the following embodiments.
Examples
As shown in fig. 1, the present embodiment provides a PLC-based pneumatic compliance device control system, the system including a cylinder having a bi-directional output force, a piston rod of the cylinder being connected to an end tool through a guide rail, the end tool acting on a machining surface, a pressure sensor for measuring a pressing force on the end tool and the machining surface, a displacement sensor for measuring a displacement of the guide rail, a pose sensor for measuring a pose of the piston rod of the cylinder, and a PLC controller for controlling a control valve of the cylinder, the pose sensor including an acceleration sensor for measuring an angle of the piston rod of the cylinder with a plumb line;
The guide rail and the end tool are used as loads, the loads are automatically weighed before the end tool acts on the machining surface, and after the end tool acts on the machining surface, the PLC collects the actual pressing force between the end tool and the machining surface, the displacement of the guide rail and the pose of a cylinder piston rod in real time, compensates the output force of the cylinder based on the load gravity, and accurately controls the pressing force between the end tool and the machining surface to keep constant.
The invention adopts a double-acting cylinder and has the function of outputting force in two directions, and the simplified function is shown in fig. 2, wherein the direction of the piston moving from the cavity a to the cavity b is regarded as positive direction, and the force applied to the positive direction is regarded as positive force. In the figures, the load to which the piston rod is connected, i.e. the end tool, is actually the cylinder piston rod connected to the end tool via a guide rail, the end tool being fixed to the guide rail. The pneumatic flexible device controls the pressure in the cylinder by the electromagnetic valve, and the piston rod moves by changing the pressure difference at the two ends of the piston rod of the cylinder, so that the cylinder generates certain output force, and the output force of the cylinder is transmitted to the end tool through the guide rail, so that the end tool generates certain pressing force on the processing surface.
The embodiment also provides a control method of the pneumatic flexible device based on the PLC, which comprises the following steps:
taking the guide rail and the tail end tool as loads, adjusting load positions, starting the air cylinder and gradually increasing the output force of the air cylinder until the displacement sensor outputs displacement, simultaneously recording the angle between the current air cylinder piston rod and the plumb line and the output force of the air cylinder, and calculating the weight of the load based on the output force of the air cylinder and the angle between the current air cylinder piston rod and the plumb line;
The method comprises the steps that an end tool acts on a machining surface, the actual compression force between the end tool and the machining surface, the displacement of a guide rail and the pose of a cylinder rod are collected in real time, the set compression force between the end tool and the machining surface is compared with the actual compression force, and the output force of a cylinder is compensated once based on load gravity to obtain a first compensation given value of the output force of the cylinder;
Based on the actual output force of the cylinder and a given value of the output force of the cylinder in the previous control period, performing secondary compensation on the output force of the cylinder by adopting an incremental PID control algorithm to obtain a second compensation given value of the output force of the cylinder;
And controlling the cylinder to work based on the second compensation given value of the output force of the cylinder.
Based on the following, the control method of the invention comprises two main contents: load automatic weighing and cylinder accurate force control are described in detail below.
First, the automatic weighing function of the load can measure the end tool mass by adjusting the output force of the cylinder, the automatic weighing flow is shown in fig. 3, and the weighing principle is shown in fig. 4. In fig. 3, m is the number of weighing times, firstly, the pneumatic flexible device is adjusted to a position where the included angle between the gravity direction of the pneumatic flexible device and the direction of the output force of the air cylinder is within 45 degrees, then the output force of the air cylinder is gradually increased by 0.1N with the minimum force control precision until the device guide rail generates 1mm displacement, the output force of the air cylinder is regarded as the weight component of the end tool under the current gesture, the end tool mass can be obtained through back-pushing, and the average value is obtained by repeatedly measuring three times to be used as the end tool mass, so that the measurement error is reduced.
As shown in fig. 5, the cylinder accurate force control includes primary and secondary compensation of the cylinder output force, specifically:
the specific mode for carrying out primary compensation on the output force of the cylinder based on the load gravity comprises the following steps:
S1, acquiring an angle between a cylinder piston rod and a plumb line, and calculating acting force F p of the gravity applied to the cylinder piston rod by the load according to the load gravity, wherein if the direction F p points to the direction of a machining surface, F p is more than 0, and otherwise F p is less than 0;
s2, acquiring actual pressing force Fr of the end tool and the processing surface in real time, and acquiring set pressing force Fs of the end tool and the processing surface at the same time;
s3, if F p is more than 0, executing a step S4, otherwise executing a step S5;
S4, if Fr is larger than Fs, F n+1,1＝Fn-|Fp -Fr-Fs is larger than F2, otherwise F n+1,1＝Fn-|Fp -Fr-Fs is larger than F2, wherein F n is a given value of output force of the cylinder at time n, and F n+1,1 is a first compensation given value of output force of the cylinder at time n+1;
S5, if Fr is larger than Fs, F n+1,1＝Fn+|Fp -Fr-Fs is larger than F2, otherwise F n+1,1＝Fn+|Fp -Fr-Fs is larger than F2, wherein F n is a given value of output force of the cylinder at time n, and F n+1,1 is a first compensation given value of output force of the cylinder at time n+1.
The specific mode for carrying out secondary compensation on the output force of the air cylinder by adopting the incremental PID control algorithm is as follows:
acquiring a cylinder output force secondary compensation value F Δ based on an incremental PID control algorithm;
calculating a second compensation given value of the output force of the cylinder: f n+1,2＝Fn+1,1+FΔ.
In step S1, F p is calculated by the following formula: f p＝Fg·cosθ,Fg is the load weight, θ is the angle of the cylinder rod with the plumb line.
F Δ is obtained by the following formula:
FΔ＝Kp(F(n)-F(n-1))+KiF(n)+Kd(F(n)-2F(n-1)+F(n-2))
F(n)＝FS(n)-Fr(n)
F(n-1)＝FS(n-1)-Fr(n-1)
F(n-2)＝FS(n-2)-Fr(n-2)
Wherein, F S(n)、FS(n-1)、FS (n-2) respectively represents the set pressing forces on the end tool and the machining surface at the time of n, the time of n-1 and the time of n-2, F r(n)、Fr(n-1)、Fr (n-2) respectively represents the actual pressing forces on the end tool and the machining surface at the time of n, the time of n-1 and the time of n-2, when n=0, F (n-1) =f (n-2) =0, and k p、Ki、Kd is a PID parameter.
The values of K p、Ki、Kd are as follows:
when the value range of the set pressing force Fs between the end tool and the processing surface is (0N, 100N), K p＝3.5,Ki＝0.02,Kd =0;
when the value range of the set pressing force Fs between the end tool and the processing surface is (100N, 200N), K p＝2.5,Ki＝0.02,Kd =0;
when the set pressing force Fs between the end tool and the working surface is in the range of (200 n,400 n), K p＝1.5,Ki＝0.02,Kd =0.
The method comprises the steps of obtaining an analog signal of an output force value of a cylinder through a force sensor, obtaining an analog signal of a guide rail position of a pneumatic compliance device through a displacement sensor, obtaining an analog signal of an angle value of the pneumatic compliance device through an acceleration sensor, connecting the analog signal to an AI module interface of a PLC, calculating and processing the analog signal into a corresponding metric value through a function corresponding to a sensor parameter, calculating by a gravity compensation and force output program of the PLC, obtaining a value of an output force of an actual cylinder, outputting a voltage signal through an AO module interface, performing voltage control on an electromagnetic valve and a proportional pressure valve, changing valve port displacement, controlling the magnitude and direction of gas flow in the cylinder, outputting a certain force to the guide rail of the pneumatic compliance device, conducting the force to a terminal tool, attaching the terminal tool to a processing surface, keeping constant force contact, and realizing constant force output.
The above embodiments are merely examples, and do not limit the scope of the present invention. These embodiments may be implemented in various other ways, and various omissions, substitutions, and changes may be made without departing from the scope of the technical idea of the present invention.
Claims (6)
1. A method for controlling a pneumatic compliance device based on a PLC, the method being based on a pneumatic compliance device control system, the system comprising:
The system comprises a cylinder with bidirectional output force, a piston rod of the cylinder is connected with an end tool through a guide rail, the end tool acts on a processing surface, and the system further comprises a pressure sensor for measuring the pressing force between the end tool and the processing surface, a displacement sensor for measuring the displacement of the guide rail, a pose sensor for measuring the pose of the piston rod of the cylinder and a PLC (programmable logic controller) for controlling a control valve of the cylinder;
Taking the guide rail and the tail end tool as loads, automatically weighing the loads before the tail end tool acts on the machining surface, and after the tail end tool acts on the machining surface, acquiring actual pressing force between the tail end tool and the machining surface, displacement of the guide rail and the pose of a cylinder piston rod in real time by the PLC, compensating the output force of the cylinder based on the load gravity, and accurately controlling the pressing force between the tail end tool and the machining surface to keep constant;
the method comprises the following steps:
Taking the guide rail and the tail end tool as loads, adjusting load positions, starting the air cylinder and gradually increasing the output force of the air cylinder until the displacement sensor outputs displacement, simultaneously recording the angle between the piston rod of the current air cylinder and the plumb line and the output force of the air cylinder, and calculating the weight of the load based on the output force of the air cylinder and the angle between the piston rod of the current air cylinder and the plumb line;
The method comprises the steps that an end tool acts on a machining surface, the actual compression force between the end tool and the machining surface, the displacement of a guide rail and the pose of a cylinder rod are collected in real time, the set compression force between the end tool and the machining surface is compared with the actual compression force, and the output force of a cylinder is compensated once based on load gravity to obtain a first compensation given value of the output force of the cylinder;
Based on the actual output force of the cylinder and a given value of the output force of the cylinder in the previous control period, performing secondary compensation on the output force of the cylinder by adopting an incremental PID control algorithm to obtain a second compensation given value of the output force of the cylinder;
controlling the cylinder to work based on the second compensation given value of the output force of the cylinder;
the specific mode for carrying out primary compensation on the output force of the cylinder based on the load gravity comprises the following steps:
S1, acquiring an angle between a cylinder piston rod and a plumb line, and calculating acting force F p of the gravity applied to the cylinder piston rod by the load according to the load gravity, wherein if the direction F p points to the direction of a machining surface, F p is more than 0, and otherwise F p is less than 0;
s2, acquiring actual pressing force Fr of the end tool and the processing surface in real time, and acquiring set pressing force Fs of the end tool and the processing surface at the same time;
s3, if F p is more than 0, executing a step S4, otherwise executing a step S5;
S4, if Fr is larger than Fs, F n+1,1＝Fn-|Fp -Fr-Fs is larger than F2, otherwise F n+1,1＝Fn-|Fp -Fr-Fs is larger than F2, wherein F n is a given value of output force of the cylinder at time n, and F n+1,1 is a first compensation given value of output force of the cylinder at time n+1;
S5, if Fr is larger than Fs, F n+1,1＝Fn+|Fp -Fr-Fs, otherwise F n+1,1＝Fn+|Fp -Fr-Fs/2, wherein F n is a given value of output force of the cylinder at time n, and F n+1,1 is a first compensation given value of output force of the cylinder at time n+1;
The specific mode for carrying out secondary compensation on the output force of the air cylinder by adopting the incremental PID control algorithm is as follows:
acquiring a cylinder output force secondary compensation value F Δ based on an incremental PID control algorithm;
Calculating a second compensation given value of the output force of the cylinder: f n+1,2＝Fn+1,1+FΔ;
f Δ is obtained by the following formula:
FΔ＝Kp(F(n)-F(n-1))+KiF(n)+Kd(F(n)-2F(n-1)+F(n-2))
F(n)＝FS(n)-Fr(n)
F(n-1)＝FS(n-1)-Fr(n-1)
F(n-2)＝FS(n-2)-Fr(n-2)
Wherein, F S(n)、FS(n-1)、FS (n-2) respectively represents the set pressing forces on the end tool and the machining surface at the time of n, the time of n-1 and the time of n-2, F r(n)、Fr(n-1)、Fr (n-2) respectively represents the actual pressing forces on the end tool and the machining surface at the time of n, the time of n-1 and the time of n-2, when n=0, F (n-1) =f (n-2) =0, and k p、Ki、Kd is a PID parameter.
2. The method of claim 1, wherein the attitude sensor comprises an acceleration sensor for measuring an angle of a cylinder rod with a plumb line.
3. The method of claim 1, wherein the load position is adjusted to: the angle between the output force direction of the air cylinder and the gravity direction of the load is 0-45 degrees.
4. The method of claim 1, wherein the cylinder output force is gradually increased by 0.1N when the load is automatically weighed.
5. The method of claim 1, wherein in step S1, F p is calculated by the following formula: f p＝Fg·cosθ,Fg is the load weight, θ is the angle of the cylinder rod with the plumb line.
6. The method for controlling a pneumatic compliance device based on a PLC according to claim 5, wherein the value of K p、Ki、Kd is as follows:
when the value range of the set pressing force Fs between the end tool and the processing surface is (0N, 100N), K p＝3.5,Ki＝0.02,Kd =0;
when the value range of the set pressing force Fs between the end tool and the processing surface is (100N, 200N), K p＝2.5,Ki＝0.02,Kd =0;
when the set pressing force Fs between the end tool and the working surface is in the range of (200 n,400 n), K p＝1.5,Ki＝0.02,Kd =0.
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