CN116880352A - Automatic control system and method for packaging equipment based on state sensing - Google Patents
Automatic control system and method for packaging equipment based on state sensing Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 17
- 238000004806 packaging method and process Methods 0.000 title claims description 23
- 238000006243 chemical reaction Methods 0.000 claims abstract description 36
- 238000012856 packing Methods 0.000 claims abstract description 31
- 238000006073 displacement reaction Methods 0.000 claims description 43
- 230000033001 locomotion Effects 0.000 claims description 21
- 239000010720 hydraulic oil Substances 0.000 claims description 18
- 239000007788 liquid Substances 0.000 claims description 16
- 239000003921 oil Substances 0.000 claims description 16
- 238000013139 quantization Methods 0.000 claims description 14
- 230000005611 electricity Effects 0.000 claims description 10
- 230000009471 action Effects 0.000 claims description 8
- 230000008859 change Effects 0.000 claims description 5
- 238000005457 optimization Methods 0.000 abstract description 4
- 230000001276 controlling effect Effects 0.000 description 27
- 238000004519 manufacturing process Methods 0.000 description 9
- 230000008569 process Effects 0.000 description 5
- 239000012530 fluid Substances 0.000 description 4
- 239000000356 contaminant Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
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- 230000004048 modification Effects 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 230000009466 transformation Effects 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
- G05B2219/1108—Relay module
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses an automatic control system and method for packing equipment based on state sensing, which belong to the technical field of automatic control, wherein the system comprises an electric control system and a hydraulic control system, the electric control system comprises state sensing equipment, a PLC (programmable logic controller) and a relay module, the state sensing equipment is used for collecting analog quantity signals in a field hydraulic control system and sending the analog quantity signals to the PLC, the PLC controls the start-stop conversion work of the relay module according to signals sent by the state sensing equipment, and the relay module controls the start-stop control of the hydraulic control system through a strong-current switch controlled by weak current. The state sensing device comprises five signal sensors, and correspondingly, the relay module also comprises five relays. The invention meets the requirements of automation, accurate positioning and adjustable control of the packing equipment, realizes comprehensive optimization of an automatic control system of the packing equipment, and improves the performance, reliability, intelligent level and safety performance of the system.
Description
Technical Field
The invention relates to a packaging equipment automatic control system and method based on state sensing, and belongs to the technical field of automatic control.
Background
The existing hydraulic packing equipment in the present country is widely applied in a plurality of engineering fields, has the characteristics of large power-weight ratio and stable movement, can realize stepless speed regulation in a large range, is easy to safely protect, has high reversing frequency, and can be self-lubricated.
However, the hydraulic system is controlled by adopting a semi-automatic control mode in the control aspect of the hydraulic packaging equipment, and the scheme is not suitable for some special environments because of high manpower consumption, high cost and high cost, and the continuous operation for a long time is not suitable, the control precision is low and errors exist.
In order to solve the defects, the automatic control system of the packing equipment based on state sensing is specially developed to meet the requirements of automation, accurate positioning and adjustability of the packing equipment.
Disclosure of Invention
In order to solve the problems, the invention provides an automatic control system and method for packing equipment based on state sensing, which can solve the problems of high cost and low control precision of the existing hydraulic packing equipment.
The technical scheme adopted for solving the technical problems is as follows:
in a first aspect, the embodiment of the invention provides an automatic control system of packing equipment based on state sensing, which comprises an electric control system and a hydraulic control system, wherein the hydraulic control system comprises a motor, a pump frame, a plunger pump, an air filter, a temperature sensor, a liquid level relay, an electric heater, a liquid level thermometer, an oil return filter, an air cooler, a tubular one-way valve, a plate one-way valve, an electromagnetic overflow valve, a pressure gauge and switch, a digital display pressure switch, a first electromagnetic directional valve, a stacked one-way throttle valve, an electrohydraulic directional valve, a stacked pressure reducing valve, a hydraulic control one-way valve, a second electromagnetic directional valve, a second hydraulic cylinder, a first hydraulic cylinder, a pressure maintaining cylinder and a third electromagnetic directional valve; the hydraulic control system uses a motor to provide a power basis, uses a hydraulic pump to convert mechanical energy into pressure, pushes hydraulic oil, and pushes a hydraulic cylinder to perform actions with different strokes and different directions by controlling various valves to change the flow direction of the hydraulic oil so as to complete different action requirements of packing equipment;
the electric control system comprises state sensing equipment, a PLC (programmable logic controller) and a relay module, wherein the state sensing equipment collects analog quantity signals in the field hydraulic control system and sends the analog quantity signals to the PLC, the PLC controls the start-stop switching operation of the relay module according to the signals sent by the state sensing equipment, and the relay module controls the start-stop of the hydraulic control system through a switch for controlling strong electricity by weak electricity;
the state sensing equipment comprises five signal sensors, wherein two signal sensors acquire motion signals of the primary hydraulic cylinder, the other two signal sensors acquire motion signals of the secondary hydraulic cylinder, and one signal sensor acquires pressure signals formed by forward pushing of the secondary hydraulic cylinder; the relay module comprises five relays, wherein two relays control a third electromagnetic directional valve of the primary hydraulic cylinder, the other two relays control a first electromagnetic directional valve of the secondary hydraulic cylinder, and one relay controls a second electromagnetic directional valve of the pressure maintaining cylinder.
As a possible implementation manner of the embodiment, the motor is connected with the plunger pump through the pump frame, hydraulic oil discharged by the hydraulic pump flows into the electromagnetic directional valve and the electromagnetic overflow valve after passing through the plate-type one-way valve to respectively control oil inlet and return of the primary hydraulic cylinder, the secondary hydraulic cylinder and the pressure maintaining cylinder and the pressure of the whole system; the digital display pressure switch controls the pressure release and pressure maintaining functions of the pressure maintaining cylinder according to pressure information generated by pushing the secondary hydraulic cylinder to the briquetting forming direction; the primary hydraulic cylinder and the secondary hydraulic cylinder compress the crushed paper into blocks with a certain proportion for packaging.
As a possible implementation manner of this embodiment, the state sensing device includes a first displacement sensor, a second displacement sensor, a first limit sensor, a second limit sensor, and a pressure sensor, where the first displacement sensor collects a displacement signal of the primary hydraulic cylinder, and the first limit sensor collects a limit signal of movement of the primary hydraulic cylinder; the second displacement sensor acquires displacement signals of the secondary hydraulic cylinder, and the second limit sensor acquires limit signals of the movement of the secondary hydraulic cylinder; the pressure sensor collects pressure signals formed by forward pushing of the secondary hydraulic cylinder.
As one possible implementation manner of this embodiment, the relay module includes a first relay, a second relay, a third relay, a fourth relay and a fifth relay, where the first relay controls the third electromagnetic directional valve of the primary hydraulic cylinder according to a displacement signal collected by the first displacement sensor, and the second relay forcedly controls the third electromagnetic directional valve of the primary hydraulic cylinder according to a limit signal collected by the first limit sensor; the third relay controls the first electromagnetic directional valve of the secondary hydraulic cylinder according to the displacement signal acquired by the second displacement sensor, and the fourth relay forcedly controls the first electromagnetic directional valve of the secondary hydraulic cylinder according to the limit signal acquired by the second limit sensor; and the fifth relay controls the second electromagnetic reversing valve of the pressure maintaining cylinder according to the pressure signal acquired by the pressure sensor.
As one possible implementation manner of this embodiment, the PLC controller includes an analog-to-digital conversion module, where the analog-to-digital conversion module is configured to:
performing high-M-bit quantization on the acquired analog signals, and converting the high-M-bit quantized code values into high-M-bit digital codes in corresponding target bits, wherein the target bits are bits for performing analog-to-digital conversion;
performing low N-M bit quantization on the acquired analog signals, and converting the acquired analog signals into low N-M bit quantized code values, wherein the low N-M bit quantized code values correspond to low N-M bit digital codes in the target bits;
and combining the high M-bit quantized code value and the N-M-bit low-bit quantized code value into an N-bit digital signal, and outputting the N-bit digital signal, wherein M, N is an integer greater than or equal to 1 and N is more than M.
As one possible implementation of this embodiment, m=n/2.
In a second aspect, an embodiment of the present invention provides a method for automatically controlling a packaging device based on state sensing, including the following steps:
under the condition that the motor provides kinetic energy, the plunger pump is started, the electromagnetic overflow valve starts to provide pressure for the system, and the temperature sensor controls the air cooler to start and stop according to the temperature signal;
the state sensing equipment collects analog quantity signals of the operation positions of the primary hydraulic cylinder and the secondary hydraulic cylinder on site and sends the analog quantity signals to the PLC;
the PLC performs digital-to-analog conversion on the received analog quantity signals and stores the data;
the PLC controller drives the third electromagnetic directional valve to control the primary hydraulic cylinder to move downwards through the relay, a displacement sensor at the lower part of the primary hydraulic cylinder receives a signal and sends the signal to the PLC controller, and the PLC controller drives the third electromagnetic directional valve to control the primary hydraulic cylinder to stop moving downwards through the relay; the first electromagnetic reversing valve is controlled to enable the second-stage hydraulic cylinder to move forwards, the pressure sensor receives a pressure signal when the second-stage hydraulic cylinder moves forwards, when the pressure signal reaches a set value, the pressure signal is sent to the PLC controller, the PLC controller drives the second electromagnetic reversing valve to control the pressure maintaining cylinder to release pressure through the other relay, meanwhile, the second-stage hydraulic cylinder moves forwards to a front limit position, the limit sensor senses that the signal is sent to the PLC controller, the PLC controller drives the first electromagnetic reversing valve to control the second-stage hydraulic cylinder to retreat, meanwhile, the third electromagnetic reversing valve is driven to control the first-stage hydraulic cylinder to ascend, and the second electromagnetic reversing valve is driven to control the pressure maintaining cylinder to open the pressure maintaining state.
As a possible implementation manner of this embodiment, the digital-to-analog conversion of the received analog signal by the PLC controller includes the following steps:
performing high-M-bit quantization on the acquired analog signals, and converting the high-M-bit quantized code values into high-M-bit digital codes in corresponding target bits, wherein the target bits are bits for performing analog-to-digital conversion;
performing low N-M bit quantization on the acquired analog signals, and converting the acquired analog signals into low N-M bit quantized code values, wherein the low N-M bit quantized code values correspond to low N-M bit digital codes in the target bits;
and combining the high M-bit quantized code value and the N-M-bit low-bit quantized code value into an N-bit digital signal, and outputting the N-bit digital signal, wherein M, N is an integer greater than or equal to 1 and N is more than M.
As one possible implementation of this embodiment, m=n/2.
The technical scheme of the embodiment of the invention has the following beneficial effects:
according to the invention, the state sensing equipment is used for collecting analog quantity data of the field hydraulic control system, and the PLC is used for controlling the relay to control the electromagnetic reversing valve to realize telescopic movement of the hydraulic cylinder, so that automatic operation of the packaging equipment in the working process is realized, the production efficiency of the packaging equipment is improved, the production cost is saved, and the labor force is reduced. The invention solves the problems of high cost and low control precision of the existing hydraulic packing equipment and meets the requirements of automation, accurate positioning and adjustability of the packing equipment. The invention realizes the comprehensive optimization of the automatic control system of the packing equipment, and improves the performance, reliability, intelligent level and safety performance of the system.
The state sensing equipment adopts the combination of the signal sensor and the relay module, acquires analog quantity signals and sends the analog quantity signals to the PLC controller, so that the start-stop conversion work of the hydraulic control system is realized. The relay module controls the switch of strong electricity through weak electricity to realize the start and stop control of the hydraulic control system. The components together form an electric control system, can realize fine control on a hydraulic control system, and has higher anti-interference capability, anti-fault capability and reliability.
The state sensing equipment adopts various sensors, and improves the acquisition accuracy and the integrity of analog quantity signals.
The invention adopts the mutual cooperation of the state sensing equipment, the PLC controller and the relay module, realizes more accurate electric control, and improves the intelligent level and the stability of the system.
The analog-to-digital conversion module realizes high-precision conversion, has high effective bit number and better monotonicity, improves the working efficiency of analog-to-digital conversion, and improves the signal quality sent by state sensing equipment.
The invention adopts the electric control transformation technology of the hydraulic control system, realizes the fine control of the hydraulic control system through the state sensing equipment, the PLC and the relay module, has higher anti-interference capability, anti-fault capability, reliability and accuracy advantages, and greatly improves the operation performance of the hydraulic control system.
Drawings
FIG. 1 is a functional block diagram of a packaging device automatic control system based on state awareness, according to an exemplary embodiment;
FIG. 2 is a schematic diagram illustrating a configuration of a state-aware based automatic control system for a bagging apparatus according to one illustrative embodiment;
FIG. 3 is a top view of the automated control system of the bagging apparatus shown in FIG. 2 based on state awareness;
fig. 4 is a flow chart illustrating a linear feedback control according to an exemplary embodiment.
Detailed Description
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
in order to clearly illustrate the technical features of the present solution, the present invention will be described in detail below with reference to the following detailed description and the accompanying drawings. The following disclosure provides many different embodiments, or examples, for implementing different structures of the invention. In order to simplify the present disclosure, components and arrangements of specific examples are described below. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. It should be noted that the components illustrated in the figures are not necessarily drawn to scale. Descriptions of well-known components and processing techniques and processes are omitted so as to not unnecessarily obscure the present invention.
Example 1
As shown in fig. 1, the automatic control system of the packaging equipment based on state sensing provided by the embodiment of the invention comprises an electric control system and a hydraulic control system, wherein the electric control system comprises state sensing equipment, a PLC (programmable logic controller) and a relay module, the state sensing equipment is used for acquiring analog quantity signals in a field hydraulic control system and sending the analog quantity signals to the PLC, the PLC controls the start-stop conversion work of the relay module according to signals sent by the state sensing equipment, and the relay module controls the start-stop control of the hydraulic control system by controlling a strong-current switch through weak current;
as shown in fig. 2 and 3, the hydraulic control system comprises a motor 1, a pump frame 2, a plunger pump 3, an air filter 4, a temperature sensor 5, a liquid level relay 6, an electric heater 7, a liquid level thermometer 8, an oil return filter 9, an air cooler 10, a pipe type one-way valve 11, a plate type one-way valve 12, an electromagnetic overflow valve 13, a pressure gauge and switch 14, a digital display pressure switch 15, a first electromagnetic directional valve 16, a stacked one-way throttle valve 17, an electro-hydraulic directional valve 18, a stacked pressure reducing valve 19, a hydraulic control one-way valve 20, a second electromagnetic directional valve 21, a second hydraulic cylinder 22, a first hydraulic cylinder 23, a pressure maintaining cylinder 24 and a third electromagnetic directional valve 25; the hydraulic control system uses a motor to provide a power basis, uses a hydraulic pump to convert mechanical energy into pressure, pushes hydraulic oil, and pushes a hydraulic cylinder to perform actions with different strokes and different directions by controlling various valves to change the flow direction of the hydraulic oil so as to complete different action requirements of packing equipment;
the state sensing equipment comprises five signal sensors, wherein two signal sensors acquire motion signals of the primary hydraulic cylinder, the other two signal sensors acquire motion signals of the secondary hydraulic cylinder, and one signal sensor acquires pressure signals formed by forward pushing of the secondary hydraulic cylinder; the relay module comprises five relays, wherein two relays control a third electromagnetic directional valve of the primary hydraulic cylinder, the other two relays control a first electromagnetic directional valve of the secondary hydraulic cylinder, and one relay controls a second electromagnetic directional valve of the pressure maintaining cylinder.
According to the invention, the state sensing equipment is used for collecting analog quantity data of the field hydraulic control system, and the PLC is used for controlling the relay to control the electromagnetic reversing valve to realize telescopic movement of the hydraulic cylinder, so that automatic operation of the packaging equipment in the working process is realized, the production efficiency of the packaging equipment is improved, the production cost is saved, and the labor force is reduced. The invention adopts the mutual cooperation of the state sensing equipment, the PLC controller and the relay module, realizes more accurate electric control, and improves the intelligent level and the stability of the system. The invention solves the problems of high cost and low control precision of the existing hydraulic packing equipment and meets the requirements of automation, accurate positioning and adjustability of the packing equipment. The invention realizes the comprehensive optimization of the automatic control system of the packing equipment, and improves the performance, reliability, intelligent level and safety performance of the system.
As a possible implementation manner of this embodiment, as shown in fig. 2 and 3, the motor 1 is connected to the plunger pump 3 through the pump frame 2, and the hydraulic oil discharged from the hydraulic pump flows into the electromagnetic directional valve and the electromagnetic overflow valve after passing through the plate-type one-way valve 12, so as to prevent the backflow of the oil path. The third electromagnetic directional valve 25, the first electromagnetic directional valve 16 and the second electromagnetic directional valve 21 respectively control the oil inlet and the oil return of the primary hydraulic cylinder 23, the secondary hydraulic cylinder 22 and the pressure maintaining cylinder 24. The electromagnetic spill valve 13 is used to control the pressure level of the entire system. The digital display pressure switch 15 controls the pressure release and pressure maintaining function of the pressure maintaining cylinder 24 according to the pressure information generated by pushing the secondary hydraulic cylinder 22 to the briquetting forming direction. The primary hydraulic cylinder 23 and the secondary hydraulic cylinder 22 are used for compressing the crushed paper into blocks with a certain proportion. The motor 1 functions to provide kinetic energy to the whole system. The plunger pump 3 is used for converting mechanical energy into hydraulic energy. The air cleaner 4 is used for removing particulate impurities in the air when hydraulic oil is added. The temperature sensor 5 converts the sensed temperature analog quantity into an output signal. The liquid level relay 6 is used for detecting the liquid level and giving a signal. The electric heater 7 is used for heating the hydraulic oil to a specified temperature. The liquid level thermometer 8 is used for displaying oil mass and oil temperature. The return filter 9 serves to filter out contaminants generated or intruded into the system before returning to the tank. The air cooler 10 is used for heat exchange by taking air as a heat exchange medium. The pipe type one-way valve 11 is used for controlling the backflow of hydraulic oil in a pipe, and the electromagnetic relief valve 13 is used for providing a constant flow rate and realizing a constant pressure in a throttle regulating system of the plunger pump 3. The electromagnetic directional valve is used for controlling the switching of the fluid direction. The stacked one-way throttle valve 17 is used for controlling the flow of liquid in a single direction, and the stacked pressure reducing valve 19 is used for playing a certain role in check in a pipeline to prevent the pipeline and the valve from being damaged. The pilot operated check valve 20 is used to control the fluid pressure and allow reverse flow through the check valve.
As one possible implementation manner of this embodiment, the state sensing device includes a first displacement sensor, a second displacement sensor, a first limit sensor, a second limit sensor, and a pressure sensor, where the first displacement sensor is used to collect a displacement signal of the primary hydraulic cylinder, and the first limit sensor is used to collect a limit signal of movement of the primary hydraulic cylinder; the second displacement sensor is used for acquiring displacement signals of the secondary hydraulic cylinder, and the second limit sensor is used for acquiring limit signals of the movement of the secondary hydraulic cylinder; the pressure sensor is used for collecting pressure signals formed by forward pushing of the secondary hydraulic cylinder. The state sensing equipment adopts various sensors, and improves the acquisition accuracy and the integrity of analog quantity signals.
As one possible implementation manner of this embodiment, the relay module includes a first relay, a second relay, a third relay, a fourth relay and a fifth relay, where the first relay is configured to control the third electromagnetic directional valve of the primary hydraulic cylinder according to a displacement signal collected by the first displacement sensor, and the second relay is configured to forcedly control the third electromagnetic directional valve of the primary hydraulic cylinder according to a limit signal collected by the first limit sensor; the third relay is used for controlling the first electromagnetic directional valve of the secondary hydraulic cylinder according to the displacement signal acquired by the second displacement sensor, and the fourth relay is used for forcedly controlling the first electromagnetic directional valve of the secondary hydraulic cylinder according to the limit signal acquired by the second limit sensor; and the fifth relay is used for controlling the second electromagnetic reversing valve of the pressure maintaining cylinder according to the pressure signal acquired by the pressure sensor.
Through the combination of the signal sensor and the relay module, the electric control system acquires analog quantity signals through the state sensing equipment and sends the analog quantity signals to the PLC, so that the start-stop conversion work of the hydraulic control system is realized. The relay module controls the switch of strong electricity through weak electricity to realize the start and stop control of the hydraulic control system. The components together form an electric control system, can realize fine control on a hydraulic control system, and has higher anti-interference capability, anti-fault capability and reliability.
As one possible implementation manner of this embodiment, the PLC controller includes an analog-to-digital conversion module, where the analog-to-digital conversion module is configured to:
performing high-M-bit quantization on the acquired analog signals, and converting the high-M-bit quantized code values into high-M-bit digital codes in corresponding target bits, wherein the target bits are bits for performing analog-to-digital conversion;
performing low N-M bit quantization on the acquired analog signals, and converting the acquired analog signals into low N-M bit quantized code values, wherein the low N-M bit quantized code values correspond to low N-M bit digital codes in the target bits;
and combining the high M-bit quantized code value and the N-M-bit low-bit quantized code value into an N-bit digital signal, and outputting the N-bit digital signal, wherein M, N is an integer greater than or equal to 1 and N is more than M.
The analog-to-digital conversion module realizes high-precision conversion, has high effective bit number and better monotonicity, improves the working efficiency of analog-to-digital conversion, and improves the signal quality sent by state sensing equipment.
As one possible implementation of this embodiment, m=n/2. In the practice of the invention, N is preferably 16.
Example 2
As shown in fig. 2, the automatic control system of the packing equipment based on state sensing provided by the embodiment of the invention comprises an electric control system and a hydraulic control system, wherein the electric control system comprises state sensing equipment, a PLC (programmable logic controller) and a relay module, and the state sensing equipment can capture analog quantity signals in the field hydraulic control system and then send the analog quantity signals to the PLC; the PLC controller controls the on and off of the relay module according to the signal received by the state sensing equipment, so as to realize the on and off control of the hydraulic control system; the relay module is used for effectively managing the hydraulic control system by controlling the on and off of strong electricity through weak electricity; the hydraulic control system uses a motor to provide a power basis, uses a hydraulic pump to convert mechanical energy into pressure, pushes hydraulic oil, and pushes a hydraulic cylinder to perform actions with different strokes and different directions by controlling various valves to change the flow direction of the hydraulic oil so as to complete different action requirements of packing equipment;
in the state sensing device, two signal sensors are used for capturing the motion signals of a first-stage hydraulic cylinder in the hydraulic control system, the other two signal sensors are used for capturing the motion signals of a second-stage hydraulic cylinder in the hydraulic control system, and one signal sensor can capture the pressure signals formed when the second-stage hydraulic cylinder in the hydraulic control system pushes forwards;
five relays are included in the relay module, wherein two relays are responsible for controlling a third electromagnetic directional valve of a first-stage hydraulic cylinder in the hydraulic control system, and the other two relays are responsible for controlling a first electromagnetic directional valve of a second-stage hydraulic cylinder in the hydraulic control system; and the last relay is used for controlling a second electromagnetic reversing valve of the pressure maintaining cylinder in the hydraulic control system.
According to the invention, the state sensing equipment is used for collecting analog quantity data of the field hydraulic control system, and the PLC is used for controlling the relay to control the electromagnetic reversing valve to realize telescopic movement of the hydraulic cylinder, so that automatic operation of the packaging equipment in the working process is realized, the production efficiency of the packaging equipment is improved, the production cost is saved, and the labor force is reduced. The invention adopts the mutual cooperation of the state sensing equipment, the PLC controller and the relay module, realizes more accurate electric control, and improves the intelligent level and the stability of the system.
As one possible implementation manner of the present embodiment, as shown in fig. 2 and 3, the hydraulic control system includes a motor 1, a pump frame 2, a plunger pump 3, an air filter 4, a temperature sensor 5, a liquid level relay 6, an electric heater 7, a liquid level thermometer 8, an oil return filter 9, an air cooler 10, a pipe type one-way valve 11, a plate type one-way valve 12, an electromagnetic relief valve 13, a pressure gauge and switch 14, a digital display pressure switch 15, a first electromagnetic directional valve 16, a superposition type one-way throttle valve 17, an electro-hydraulic directional valve 18, a superposition type pressure reducing valve 19, a hydraulic control one-way valve 20, a second electromagnetic directional valve 21, a second hydraulic cylinder 22, a first hydraulic cylinder 23, a pressure maintaining cylinder 24 and a third electromagnetic directional valve 25;
the motor 1 is connected with the plunger pump 3 through the pump frame 2, and hydraulic oil discharged by the hydraulic pump flows into the electromagnetic reversing valve and the electromagnetic overflow valve after passing through the plate-type one-way valve 12, so that backflow of an oil way is prevented; the third electromagnetic directional valve 25, the first electromagnetic directional valve 16 and the second electromagnetic directional valve 21 respectively control the oil inlet and the oil return of the primary hydraulic cylinder 23, the secondary hydraulic cylinder 22 and the pressure maintaining cylinder 24; the electromagnetic relief valve 13 is used for controlling the pressure of the whole system; the digital display pressure switch 15 controls the pressure release and pressure maintaining function of the pressure maintaining cylinder 24 according to the pressure information generated by pushing the secondary hydraulic cylinder to the briquetting forming direction; the primary hydraulic cylinder 23 and the secondary hydraulic cylinder 22 compress the crushed paper into blocks with a certain proportion for packing.
As a possible implementation of this embodiment, the motor 1 functions to provide kinetic energy to the whole system. The plunger pump 3 is used for converting mechanical energy into hydraulic energy. The air cleaner 4 is used for removing particulate impurities in the air when hydraulic oil is added. The temperature sensor 5 converts the sensed temperature analog quantity into an output signal. The liquid level relay 6 is used for detecting the liquid level and giving a signal. The electric heater 7 is used for heating the hydraulic oil to a specified temperature. The liquid level thermometer 8 is used for displaying oil mass and oil temperature. The return filter 9 serves to filter out contaminants generated or intruded into the system before returning to the tank. The air cooler 10 is used for heat exchange by taking air as a heat exchange medium. The pipe type one-way valve 11 is used for controlling the backflow of hydraulic oil in a pipe, and the electromagnetic relief valve 13 is used for providing a constant flow rate and realizing a constant pressure in a throttle regulating system of the plunger pump 3. The electromagnetic directional valve is used for controlling the switching of the fluid direction. The stacked one-way throttle valve 17 is used for controlling the flow of liquid in a single direction, and the stacked pressure reducing valve 19 is used for playing a certain role in check in a pipeline to prevent the pipeline and the valve from being damaged. The pilot operated check valve 20 is used to control the fluid pressure and allow reverse flow through the check valve.
As one possible implementation manner of this embodiment, the state sensing device includes a first displacement sensor, a second displacement sensor, a first limit sensor, a second limit sensor, and a pressure sensor, where the first displacement sensor is used to collect a displacement signal of the primary hydraulic cylinder, and the first limit sensor is used to collect a limit signal of movement of the primary hydraulic cylinder; the second displacement sensor is used for acquiring displacement signals of the secondary hydraulic cylinder, and the second limit sensor is used for acquiring limit signals of the movement of the secondary hydraulic cylinder; the pressure sensor is connected with a digital display pressure switch 15 and is used for collecting pressure signals formed by forward pushing of the secondary hydraulic cylinder. The state sensing equipment adopts various sensors, and improves the acquisition accuracy and the integrity of analog quantity signals.
As one possible implementation manner of this embodiment, the relay module includes a first relay, a second relay, a third relay, a fourth relay and a fifth relay, where the first relay is configured to control the third electromagnetic directional valve of the primary hydraulic cylinder according to a displacement signal collected by the first displacement sensor, and the second relay is configured to forcedly control the third electromagnetic directional valve of the primary hydraulic cylinder according to a limit signal collected by the first limit sensor; the third relay is used for controlling the first electromagnetic directional valve of the secondary hydraulic cylinder according to the displacement signal acquired by the second displacement sensor, and the fourth relay is used for forcedly controlling the first electromagnetic directional valve of the secondary hydraulic cylinder according to the limit signal acquired by the second limit sensor; and the fifth relay is used for controlling the second electromagnetic reversing valve of the pressure maintaining cylinder according to the pressure signal acquired by the pressure sensor.
As one possible implementation manner of this embodiment, the PLC controller includes an analog-to-digital conversion module, where the analog-to-digital conversion module is configured to:
performing high-M-bit quantization on the acquired analog signals, and converting the high-M-bit quantized code values into high-M-bit digital codes in corresponding target bits, wherein the target bits are bits for performing analog-to-digital conversion;
performing low N-M bit quantization on the acquired analog signals, and converting the acquired analog signals into low N-M bit quantized code values, wherein the low N-M bit quantized code values correspond to low N-M bit digital codes in the target bits;
and combining the high M-bit quantized code value and the N-M-bit low-bit quantized code value into an N-bit digital signal, and outputting the N-bit digital signal, wherein M, N is an integer greater than or equal to 1 and N is more than M.
The analog-to-digital conversion module realizes high-precision conversion, has high effective bit number and better monotonicity, improves the working efficiency of analog-to-digital conversion, and improves the signal quality sent by state sensing equipment.
As one possible implementation of this embodiment, m=n/2. In the practice of the invention, N is preferably 16.
Example 3
The embodiment of the invention provides a packaging equipment automatic control method based on state sensing, which comprises the following steps:
under the condition that the motor provides kinetic energy, the plunger pump is started, the electromagnetic overflow valve starts to provide pressure for the system, and the temperature sensor controls the air cooler to start and stop according to the temperature signal;
the state sensing equipment collects analog quantity signals of the operation positions of the primary hydraulic cylinder and the secondary hydraulic cylinder on site and sends the analog quantity signals to the PLC;
the PLC performs digital-to-analog conversion on the received analog quantity signals and stores the data;
the PLC controller drives the third electromagnetic directional valve to control the primary hydraulic cylinder to move downwards through the relay, a displacement sensor at the lower part of the primary hydraulic cylinder receives a signal and sends the signal to the PLC controller, and the PLC controller drives the third electromagnetic directional valve to control the primary hydraulic cylinder to stop moving downwards through the relay; the first electromagnetic reversing valve is controlled to enable the second-stage hydraulic cylinder to move forwards, the pressure sensor receives a pressure signal when the second-stage hydraulic cylinder moves forwards, when the pressure signal reaches a set value, the pressure signal is sent to the PLC controller, the PLC controller drives the second electromagnetic reversing valve to control the pressure maintaining cylinder to release pressure through the other relay, meanwhile, the second-stage hydraulic cylinder moves forwards to a front limit position, the limit sensor senses that the signal is sent to the PLC controller, the PLC controller drives the first electromagnetic reversing valve to control the second-stage hydraulic cylinder to retreat, meanwhile, the third electromagnetic reversing valve is driven to control the first-stage hydraulic cylinder to ascend, and the second electromagnetic reversing valve is driven to control the pressure maintaining cylinder to open the pressure maintaining state.
As a possible implementation manner of this embodiment, the digital-to-analog conversion of the received analog signal by the PLC controller includes the following steps:
performing high-M-bit quantization on the acquired analog signals, and converting the high-M-bit quantized code values into high-M-bit digital codes in corresponding target bits, wherein the target bits are bits for performing analog-to-digital conversion;
performing low N-M bit quantization on the acquired analog signals, and converting the acquired analog signals into low N-M bit quantized code values, wherein the low N-M bit quantized code values correspond to low N-M bit digital codes in the target bits;
and combining the high M-bit quantized code value and the N-M-bit low-bit quantized code value into an N-bit digital signal, and outputting the N-bit digital signal, wherein M, N is an integer greater than or equal to 1 and N is more than M.
The analog-to-digital conversion module realizes high-precision conversion, has high effective bit number and better monotonicity, improves the working efficiency of analog-to-digital conversion, and improves the signal quality sent by state sensing equipment.
As one possible implementation of this embodiment, m=n/2. In the practice of the invention, N is preferably 16.
The PLC controller is a brain of the whole system, received signals are firstly collected into the PLC, the PLC outputs to control the relay module and finally transmitted to the hydraulic system, the hydraulic system controls the flow of equipment, and the system mainly controls the operation flow of hydraulic cylinders at all levels and information feedback to realize the normal operation of the pressure-maintaining electrohydraulic control system of the hydraulic cylinders.
According to the invention, the state sensing equipment is used for collecting analog quantity data of the field hydraulic control system, and the PLC is used for controlling the relay to control the electromagnetic reversing valve to realize telescopic movement of the hydraulic cylinder, so that automatic operation of the packaging equipment in the working process is realized, the production efficiency of the packaging equipment is improved, the production cost is saved, and the labor force is reduced. The invention adopts the mutual cooperation of the state sensing equipment, the PLC controller and the relay module, realizes more accurate electric control, and improves the intelligent level and the stability of the system.
The invention is a linear feedback control system, as shown in fig. 4, the system control can automatically recover to the original equilibrium state from the initial deviation. The input quantity is constant or varies with time, and the main task of the system is to keep the actual output quantity of the system at or near the expected value when interference is received. The system is stable and has a certain stability margin, and the judgment basis comprises any one of a Rough (Routh) stability criterion and a Nyquist (Nyquist) stability criterion. The characteristic equation of the system isThe relative stability of an automatic control system of the packing equipment based on state sensing is measured according to a stability margin, wherein the relative stability is mainly obtained according to the open-loop logarithmic frequency characteristic of the automatic control system of the packing equipment based on state sensing by using a phase margin gamma and a gain margin K; the expression of the phase margin gamma is gamma=180 degrees+ψ>）,/>For gain crossover or crossover frequency, gamma>0 is positive phase margin, gamma<0 is the negative phase margin. And the gain margin k is expressed as: k= -L (ω) 1 ）, ω 1 Is the phase crossover frequency. K (K)>0 is the positive gain margin and,K<0 is the negative gain margin.
The system is a control system with high precision and high quality control, and the automatic control system of the packing equipment based on state sensing is analyzed according to frequency, and is mainly analyzed according to a phase margin gamma and a gain margin K.
The invention realizes the whole system operation according to the linear feedback mode, can realize the continuous working state and improves the production efficiency. The feedback type is shown in fig. 4, μ is an input signal, mainly from a signal determined or changed outside the system, which can determine the change rule of the controlled variable; r is a reference input for inputting a signal and comparing with a main feedback signal; b is a main feedback signal, which is a function of the controlled quantity; epsilon is the deviation signal; c is an output signal; e is an error signal; f is an interference signal;
wherein the pressure signal is used as sample data, the pressure signal is used as input, the medium type corresponding to the pressure signal is used as output, a medium classification model is trained by adopting a mathematical algorithm, and the general form is thatX is the input of the component or system, y is the output of the component or system, < >>、/>、/>，/>、/>、/>The constant coefficients determined for the structural parameters of the system, the actual system, all satisfy m.
The invention solves the problems of high cost and low control precision of the existing hydraulic packing equipment and meets the requirements of automation, accurate positioning and adjustability of the packing equipment. The invention realizes the comprehensive optimization of the automatic control system of the packing equipment, and improves the performance, reliability, intelligent level and safety performance of the system.
Finally, it should be noted that: the above embodiments are only for illustrating the technical aspects of the present invention and not for limiting the same, and although the present invention has been described in detail with reference to the above embodiments, it should be understood by those of ordinary skill in the art that: modifications and equivalents may be made to the specific embodiments of the invention without departing from the spirit and scope of the invention, which is intended to be covered by the claims.
Claims (9)
1. The automatic control system of the packing equipment based on state sensing comprises an electric control system and a hydraulic control system, wherein the hydraulic control system comprises a motor, a pump frame, a plunger pump, an air filter, a temperature sensor, a liquid level relay, an electric heater, a liquid level thermometer, an oil return filter, an air cooler, a tubular one-way valve, a plate one-way valve, an electromagnetic overflow valve, a pressure gauge and a switch, a digital display pressure switch, a first electromagnetic directional valve, a stacked one-way throttle valve, an electrohydraulic directional valve, a stacked pressure reducing valve, a hydraulic control one-way valve, a second electromagnetic directional valve, a second hydraulic cylinder, a first hydraulic cylinder, a pressure maintaining cylinder and a third electromagnetic directional valve; the hydraulic control system uses a motor to provide a power basis, uses a hydraulic pump to convert mechanical energy into pressure, pushes hydraulic oil, and pushes a hydraulic cylinder to perform actions with different strokes and different directions by controlling various valves to change the flow direction of the hydraulic oil so as to complete different action requirements of packing equipment; it is characterized in that the method comprises the steps of,
the electric control system comprises state sensing equipment, a PLC (programmable logic controller) and a relay module, wherein the state sensing equipment collects analog quantity signals in the field hydraulic control system and sends the analog quantity signals to the PLC, the PLC controls the start-stop switching operation of the relay module according to the signals sent by the state sensing equipment, and the relay module controls the start-stop of the hydraulic control system through a switch for controlling strong electricity by weak electricity;
the state sensing equipment comprises five signal sensors, wherein two signal sensors acquire motion signals of the primary hydraulic cylinder, the other two signal sensors acquire motion signals of the secondary hydraulic cylinder, and one signal sensor acquires pressure signals formed by forward pushing of the secondary hydraulic cylinder; the relay module comprises five relays, wherein two relays control a third electromagnetic directional valve of the primary hydraulic cylinder, the other two relays control a first electromagnetic directional valve of the secondary hydraulic cylinder, and one relay controls a second electromagnetic directional valve of the pressure maintaining cylinder.
2. The automatic control system of packing equipment based on state sensing according to claim 1, wherein the motor is connected with the plunger pump through a pump frame, hydraulic oil discharged by the hydraulic pump flows into the electromagnetic directional valve and the electromagnetic overflow valve after passing through the plate-type one-way valve to respectively control the oil inlet and return of the primary hydraulic cylinder, the secondary hydraulic cylinder and the pressure maintaining cylinder and the pressure of the whole system; the digital display pressure switch controls the pressure release and pressure maintaining functions of the pressure maintaining cylinder according to pressure information generated by pushing the secondary hydraulic cylinder to the briquetting forming direction; the primary hydraulic cylinder and the secondary hydraulic cylinder compress the crushed paper into blocks with a certain proportion for packaging.
3. The automatic control system of a packaging device based on state sensing according to claim 1, wherein the state sensing device comprises a first displacement sensor, a second displacement sensor, a first limit sensor, a second limit sensor and a pressure sensor, the first displacement sensor collects displacement signals of the primary hydraulic cylinder, and the first limit sensor collects limit signals of movement of the primary hydraulic cylinder; the second displacement sensor acquires displacement signals of the secondary hydraulic cylinder, and the second limit sensor acquires limit signals of the movement of the secondary hydraulic cylinder; the pressure sensor collects pressure signals formed by forward pushing of the secondary hydraulic cylinder.
4. The automatic control system of a packaging device based on state sensing according to claim 3, wherein the relay module comprises a first relay, a second relay, a third relay, a fourth relay and a fifth relay, the first relay controls a third electromagnetic directional valve of the primary hydraulic cylinder according to a displacement signal acquired by a first displacement sensor, and the second relay forcedly controls the third electromagnetic directional valve of the primary hydraulic cylinder according to a limit signal acquired by a first limit sensor; the third relay controls the first electromagnetic directional valve of the secondary hydraulic cylinder according to the displacement signal acquired by the second displacement sensor, and the fourth relay forcedly controls the first electromagnetic directional valve of the secondary hydraulic cylinder according to the limit signal acquired by the second limit sensor; and the fifth relay controls the second electromagnetic reversing valve of the pressure maintaining cylinder according to the pressure signal acquired by the pressure sensor.
5. The automated packaging equipment control system based on state awareness according to any one of claims 1-4, wherein the PLC controller includes an analog to digital conversion module configured to:
performing high-M-bit quantization on the acquired analog signals, and converting the high-M-bit quantized code values into high-M-bit digital codes in corresponding target bits, wherein the target bits are bits for performing analog-to-digital conversion;
performing low N-M bit quantization on the acquired analog signals, and converting the acquired analog signals into low N-M bit quantized code values, wherein the low N-M bit quantized code values correspond to low N-M bit digital codes in the target bits;
and combining the high M-bit quantized code value and the N-M-bit low-bit quantized code value into an N-bit digital signal, and outputting the N-bit digital signal, wherein M, N is an integer greater than or equal to 1 and N is more than M.
6. The state-aware based packing apparatus automatic control system according to claim 5, wherein m=n/2.
7. The automatic control method of the packing equipment based on state sensing is characterized by comprising the following steps of:
under the condition that the motor provides kinetic energy, the plunger pump is started, the electromagnetic overflow valve starts to provide pressure for the system, and the temperature sensor controls the air cooler to start and stop according to the temperature signal;
the state sensing equipment collects analog quantity signals of the operation positions of the primary hydraulic cylinder and the secondary hydraulic cylinder on site and sends the analog quantity signals to the PLC;
the PLC performs digital-to-analog conversion on the received analog quantity signals and stores the data;
the PLC controller drives the third electromagnetic directional valve to control the primary hydraulic cylinder to move downwards through the relay, a displacement sensor at the lower part of the primary hydraulic cylinder receives a signal and sends the signal to the PLC controller, and the PLC controller drives the third electromagnetic directional valve to control the primary hydraulic cylinder to stop moving downwards through the relay; the first electromagnetic reversing valve is controlled to enable the second-stage hydraulic cylinder to move forwards, the pressure sensor receives a pressure signal when the second-stage hydraulic cylinder moves forwards, when the pressure signal reaches a set value, the pressure signal is sent to the PLC controller, the PLC controller drives the second electromagnetic reversing valve to control the pressure maintaining cylinder to release pressure through the other relay, meanwhile, the second-stage hydraulic cylinder moves forwards to a front limit position, the limit sensor senses that the signal is sent to the PLC controller, the PLC controller drives the first electromagnetic reversing valve to control the second-stage hydraulic cylinder to retreat, meanwhile, the third electromagnetic reversing valve is driven to control the first-stage hydraulic cylinder to ascend, and the second electromagnetic reversing valve is driven to control the pressure maintaining cylinder to open the pressure maintaining state.
8. The automatic control method of a packaging device based on state sensing according to claim 7, wherein the PLC controller performs digital-to-analog conversion on the received analog signal, comprising the steps of:
performing high-M-bit quantization on the acquired analog signals, and converting the high-M-bit quantized code values into high-M-bit digital codes in corresponding target bits, wherein the target bits are bits for performing analog-to-digital conversion;
performing low N-M bit quantization on the acquired analog signals, and converting the acquired analog signals into low N-M bit quantized code values, wherein the low N-M bit quantized code values correspond to low N-M bit digital codes in the target bits;
and combining the high M-bit quantized code value and the N-M-bit low-bit quantized code value into an N-bit digital signal, and outputting the N-bit digital signal, wherein M, N is an integer greater than or equal to 1 and N is more than M.
9. The automatic control method of a packaging apparatus based on state sensing according to claim 8, wherein m=n/2.
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