High-stability double-sliding-bell screw control system and control method thereof
阅读说明：本技术 一种高稳定性双滑铃丝杠控制系统及其控制方法 (High-stability double-sliding-bell screw control system and control method thereof ) 是由 陈杰 夏惊秋 沈馗 于 2019-03-21 设计创作，主要内容包括：本发明公开了一种高稳定性双滑铃丝杠控制系统及其控制方法,由系统速度给定模块输出给定值,送至预调单元对给定值信号与前置处理单元送来的信号进行预处理后,通过系统比较运算单元送至前置处理单元进行信号隔离、前置处理后,再将信号送至控制单元对信号进行数据运算处理,处理的信号经输出单元送至比例阀组来驱动控制液压马达,液压马达旋转带动丝杠组件传动,比例阀组驱动同时将其阀开度信号反馈至控制单元；丝杠组件上设有编码器,将检测的位置值送至系统比较运算单元与经预调单元处理的设定目标位置值进行比较运算,改进比例阀组将其本体状态信号反馈至控制单元。本发明实现焊机高精度双滑铃丝杠部件稳定长效使用及焊接质量的可靠稳定控制。(The invention discloses a high-stability double-sliding-bell screw control system and a control method thereof.A given value is output by a system speed given module, a given value signal and a signal sent by a pre-processing unit are pre-processed by a preset unit, the given value signal and the signal are sent to the pre-processing unit for signal isolation and pre-processing by a system comparison operation unit, the signal is sent to a control unit for data operation processing, the processed signal is sent to a proportional valve bank through an output unit to drive and control a hydraulic motor, the hydraulic motor rotates to drive a screw assembly to transmit, and the proportional valve bank drives and feeds back a valve opening signal to the control unit; the screw assembly is provided with an encoder, the detected position value is sent to a system comparison operation unit to be compared with a set target position value processed by a preset unit, and the improved proportional valve group feeds back a body state signal to the control unit. The invention realizes the stable and long-term use of high-precision double-sliding-bell screw components of the welding machine and the reliable and stable control of the welding quality.)
1. The utility model provides a two ballscrew control systems of high stability, includes hydraulic motor, lead screw assembly, its characterized in that: the system also comprises a system speed setting module, a preset unit, a system comparison operation unit, a preprocessing unit, a control unit, an output unit and a proportional valve bank;
the system speed setting module outputs a set value and sends the set value to the pre-adjusting unit, the pre-adjusting unit preprocesses a set value signal and a signal sent by the pre-processing unit, the signal is sent to the pre-processing unit through the system comparison operation unit for signal isolation and preprocessing, and then the signal is sent to the control unit for data operation processing, the processed signal is sent to the proportional valve bank through the output unit to drive and control the hydraulic motor, the hydraulic motor rotates to drive the lead screw assembly for transmission, and the proportional valve bank drives and simultaneously feeds back a valve opening signal to the control unit;
the screw assembly is provided with an encoder, and a position value detected by the encoder is sent to a system comparison operation unit to be compared with a set target position value processed by a preset unit, so that the improved proportional valve group feeds back a state signal of the body to the control unit.
2. The high stability dual ballscrew control system of claim 1, further comprising: the hydraulic motor and the lead screw assembly are respectively provided with a temperature detector and a vibration detector, the temperature detector and the vibration detector feed back detected temperature and vibration signals to the pre-processing unit, the pre-adjusting unit is controlled after processing, and pre-intervention processing under abnormal conditions is achieved.
3. The high stability dual ballscrew control system of claim 1, further comprising: the front-end processing unit is also connected with an HMI.
4. The high stability dual ballscrew control system of claim 1, further comprising: the pre-processing unit is a SIMATIC S7-400 programmable computer controller.
5. A high stability dual-ballscrew control method as set forth in any of claims 1 to 4, characterized in that: comprises that
Outputting zero drift detection and adjustment treatment through a proportional valve group:
when the pressure difference value of the hydraulic motor is less than or equal to 10bar, the normal condition is adopted;
when the pressure difference value of the hydraulic motor is more than 10bar and less than or equal to 15bar, the system reminds that adjustment is needed, and the stop valve is turned off in a delayed mode of 1S;
when the differential pressure value of the hydraulic motor is more than 15bar and less than or equal to 25bar, the system outputs an alarm, the stop valve cancels delayed turn-off, and the proportional valve group outputs zero drift calibration;
when the pressure difference value of the hydraulic motor is more than or equal to 25bar, the system breaks down, stops output driving, immediately stops, and adjusts the proportional valve group to output zero drift;
by encoder position detection and pre-adjustment:
when the position lag deviation value is larger than 1mm and less than or equal to 2mm, the speed is set to be reduced by 2-5% by the preposed processing unit;
when the position lag deviation value is larger than 2mm and less than or equal to 5mm, the speed is set to be reduced by 5-10% by the preposed processing unit;
when the position lag deviation value is more than 5mm and less than or equal to 10mm, the speed is set to be reduced by 10-20% by the preposed processing unit;
when the position lag deviation value is larger than 10mm, the speed is set to be reduced by 25% by the front processing unit;
temperature detection and pre-adjustment through a temperature detector:
when the temperature rise value compared with the ambient temperature is more than 5 ℃ and less than or equal to 10 ℃, the speed is set to be reduced by 1-5% by the pre-processing unit;
when the temperature rise value compared with the ambient temperature is more than 10 ℃ and less than or equal to 15 ℃, the speed is set to be reduced by 5-10% by the pre-processing unit;
when the temperature rise value compared with the ambient temperature is more than 15 ℃ and less than or equal to 25 ℃, the speed is set to be reduced by 10-20% by the pre-processing unit;
when the temperature rise value compared with the ambient temperature is more than 25 ℃, the speed is given to be reduced by 25% by the pre-processing unit;
vibration detection and pre-adjustment through a vibration detector:
when the vibration detection value is more than 3 filaments and less than or equal to 5 filaments, the speed is set to be reduced by 1-5% by the pre-processing unit;
when the vibration detection value is more than 5 filaments and less than or equal to 10 filaments, the speed is set to be reduced by 5-10% by the pre-processing unit;
when the vibration detection value is more than 10 filaments and less than or equal to 20 filaments, the speed is set to be reduced by 10-20% by the pre-processing unit;
when the vibration detection value is more than 20 wires, the pre-processing unit adjusts the speed downward by 25%.
6. The high stability dual ballscrew control method of claim 5, wherein: the preprocessing unit carries out comparison and analysis according to the fed-back detection value and a set model, then carries out data exchange with the control unit, carries out preset processing on the given value, simultaneously displays the preprocessing information on the HMI, increases warning and analysis guidance display when the abnormality reaches the set value, and guides operation and maintenance personnel to carry out accurate coping processing.
7. The high stability dual ballscrew control method of claim 6, wherein: the method for guiding the operation and maintenance personnel to perform accurate handling comprises the following specific steps:
when the preset processing unit lowers the speed by less than or equal to 5%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are prompted, specifically, the lowering is caused by one or more factors of vibration, temperature, hysteresis or zero drift, and the operation and maintenance personnel are guided to carry out targeted inspection and maintenance on relevant parts of the driving system;
when the preset processing unit reduces the speed setting by more than 5% and less than or equal to 10%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are warned, the relative mechanism of the double-sliding-bell screw is obviously degraded, and the operation and maintenance personnel are guided to disassemble, check and maintain the double-sliding-bell screw, the hydraulic motor and the mechanical transmission structure on the basis of oil supplement, cleaning and fastening;
when the preset processing unit reduces the speed by more than 10% and less than or equal to 20%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are warned that the double-sliding-bell screw system is seriously degraded and has obvious fault points, the operation and maintenance personnel are guided to check the fault points in the next overhaul downtime, and a fault point prompt list is listed;
when the preset processing unit reduces the speed set by more than 20%, information is transmitted to the HMI, operation and maintenance personnel are seriously warned, the double-sliding-bell screw system of the welding machine can be locked in a fault at any time and can not continue welding, the normal operation requirement of the machine set can not be met, the operation and maintenance personnel are guided to reduce the operation speed of the machine set, the process section is properly adjusted, emergency measures are immediately adopted, and safety accidents and production accidents possibly caused by sudden faults or damage of the double-sliding-bell screw system are avoided.
Technical Field
The invention relates to the field of drive control of a screw rod of transmission equipment, in particular to a high-stability double-sliding-bell-screw control system and a control method thereof, which are particularly suitable for the field of drive control of double-sliding-bell-screw of welding machine equipment.
Background
The cold rolling secondary cooling unit acid rolling machine set adopts a laser welding machine, a driving control system of a high-precision double-sliding bell screw component adopts a B & R2010 controller, the controller has higher control precision, but the control output is solidified and can not be correspondingly adjusted along with the change of the load, in addition, the program is a modularized design of a built-in system block, the equipment maintenance personnel can not read the program, however, the method is a common classical pure closed-loop control system analyzed from the actual control effect, once the actual speed of the high-precision double-sliding-bell screw component of the welding machine cannot reach the set speed, the component cannot act and the welding machine cannot weld, so that the welding machine is easy to make mistakes and has poor reliability, the control system can not completely meet the drive control requirement of the high-precision double-sliding-bell screw component, seriously influences the full continuous production of a unit, influences the product quality, and can also cause production equipment accidents in serious cases.
As shown in figure 1, the high-precision double-ring lead screw control system of the existing welding machine equipment is a common classical pure closed-loop control system, a system speed setting module sets 15mpm (10V), the high-precision double-ring lead screw control system is sent to an interface unit 2 of an intelligent module NC303 through a system comparison module 1 to be subjected to signal isolation processing, a module control unit 3 performs logic amplification processing on an input signal, the amplified signal is sent to a proportional valve bank 5 through an output unit 4 to drive and control a hydraulic motor 6, the hydraulic motor 6 rotates to drive a lead screw component 7 to be transmitted, the proportional valve bank 5 drives and simultaneously feeds back a valve opening signal to the module control unit 3, an encoder 8 arranged on the lead screw component 7 sends a detected position value to the system comparison module 1 to be compared with a set target position value, adjustment is performed according to a comparison result, if the set value reaches a maximum limit amplitude of 10V, the position value is still 5% later, the system reports a driving fault, and welding cannot be carried out.
Therefore, the control mode cannot adjust the given speed of the double-sliding-bell-screw component of the welding machine in real time according to the change condition of the transmission state of the welding machine, and an effective matching adjustment method is not available, so that the high-precision double-sliding-bell-screw component of the welding machine is low in driving control reliability, high in failure rate, unstable in welding and easy to generate driving control failure, the double-sliding-bell-screw component of the welding machine is lack of targeted protection and optimized maintenance measures, and is easy to deteriorate and even suddenly damage, and the quality of a welding seam is influenced.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a high-stability double-sliding-bell-screw control system and a control method thereof, which can realize the stable and long-acting use of high-precision double-sliding-bell-screw components of a welding machine and the reliable and stable control of welding quality.
In order to achieve the purpose, the invention adopts the following technical scheme:
on the one hand, two ballscrew control systems of high stability, including hydraulic motor, lead screw assembly, its characterized in that: the system also comprises a system speed setting module, a preset unit, a system comparison operation unit, a preprocessing unit, a control unit, an output unit and a proportional valve bank;
the system speed setting module outputs a set value and sends the set value to the pre-adjusting unit, the pre-adjusting unit preprocesses a set value signal and a signal sent by the pre-processing unit, the signal is sent to the pre-processing unit through the system comparison operation unit for signal isolation and preprocessing, and then the signal is sent to the control unit for data operation processing, the processed signal is sent to the proportional valve bank through the output unit to drive and control the hydraulic motor, the hydraulic motor rotates to drive the lead screw assembly for transmission, and the proportional valve bank drives and simultaneously feeds back a valve opening signal to the control unit;
the screw assembly is provided with an encoder, and a position value detected by the encoder is sent to a system comparison operation unit to be compared with a set target position value processed by a preset unit, so that the improved proportional valve group feeds back a state signal of the body to the control unit.
The hydraulic motor and the lead screw assembly are respectively provided with a temperature detector and a vibration detector, the temperature detector and the vibration detector feed back detected temperature and vibration signals to the pre-processing unit, the pre-adjusting unit is controlled after processing, and pre-intervention processing under abnormal conditions is achieved.
The front-end processing unit is also connected with an HMI.
The pre-processing unit is a SIMATIC S7-400 programmable computer controller.
On the other hand, the high-stability double-sliding-bell screw control method comprises the following steps:
outputting zero drift detection and adjustment treatment through a proportional valve group:
when the pressure difference value of the hydraulic motor is less than or equal to 10bar, the normal condition is adopted;
when the pressure difference value of the hydraulic motor is more than 10bar and less than or equal to 15bar, the system reminds that adjustment is needed, and the stop valve is turned off in a delayed mode of 1S;
when the differential pressure value of the hydraulic motor is more than 15bar and less than or equal to 25bar, the system outputs an alarm, the stop valve cancels delayed turn-off, and the proportional valve group outputs zero drift calibration;
when the pressure difference value of the hydraulic motor is more than or equal to 25bar, the system breaks down, stops output driving, immediately stops, and adjusts the proportional valve group to output zero drift;
by encoder position detection and pre-adjustment:
when the position lag deviation value is larger than 1mm and less than or equal to 2mm, the speed is set to be reduced by 2-5% by the preposed processing unit;
when the position lag deviation value is larger than 2mm and less than or equal to 5mm, the speed is set to be reduced by 5-10% by the preposed processing unit;
when the position lag deviation value is more than 5mm and less than or equal to 10mm, the speed is set to be reduced by 10-20% by the preposed processing unit;
when the position lag deviation value is larger than 10mm, the speed is set to be reduced by 25% by the front processing unit;
temperature detection and pre-adjustment through a temperature detector:
when the temperature rise value compared with the ambient temperature is more than 5 ℃ and less than or equal to 10 ℃, the speed is set to be reduced by 1-5% by the pre-processing unit;
when the temperature rise value compared with the ambient temperature is more than 10 ℃ and less than or equal to 15 ℃, the speed is set to be reduced by 5-10% by the pre-processing unit;
when the temperature rise value compared with the ambient temperature is more than 15 ℃ and less than or equal to 25 ℃, the speed is set to be reduced by 10-20% by the pre-processing unit;
when the temperature rise value compared with the ambient temperature is more than 25 ℃, the speed is given to be reduced by 25% by the pre-processing unit;
vibration detection and pre-adjustment through a vibration detector:
when the vibration detection value is more than 3 filaments and less than or equal to 5 filaments, the speed is set to be reduced by 1-5% by the pre-processing unit;
when the vibration detection value is more than 5 filaments and less than or equal to 10 filaments, the speed is set to be reduced by 5-10% by the pre-processing unit;
when the vibration detection value is more than 10 filaments and less than or equal to 20 filaments, the speed is set to be reduced by 10-20% by the pre-processing unit;
when the vibration detection value is more than 20 wires, the pre-processing unit adjusts the speed downward by 25%.
The preprocessing unit carries out comparison and analysis according to the fed-back detection value and a set model, then carries out data exchange with the control unit, carries out preset processing on the given value, simultaneously displays the preprocessing information on the HMI, increases warning and analysis guidance display when the abnormality reaches the set value, and guides operation and maintenance personnel to carry out accurate coping processing.
The method for guiding the operation and maintenance personnel to perform accurate handling comprises the following specific steps:
when the preset processing unit lowers the speed by less than or equal to 5%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are prompted, specifically, the lowering is caused by one or more factors of vibration, temperature, hysteresis or zero drift, and the operation and maintenance personnel are guided to carry out targeted inspection and maintenance on relevant parts of the driving system;
when the preset processing unit reduces the speed setting by more than 5% and less than or equal to 10%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are warned, the relative mechanism of the double-sliding-bell screw is obviously degraded, and the operation and maintenance personnel are guided to disassemble, check and maintain the double-sliding-bell screw, the hydraulic motor and the mechanical transmission structure on the basis of oil supplement, cleaning and fastening;
when the preset processing unit reduces the speed by more than 10% and less than or equal to 20%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are warned that the double-sliding-bell screw system is seriously degraded and has obvious fault points, the operation and maintenance personnel are guided to check the fault points in the next overhaul downtime, and a fault point prompt list is listed;
when the preset processing unit reduces the speed set by more than 20%, information is transmitted to the HMI, operation and maintenance personnel are seriously warned, the double-sliding-bell screw system of the welding machine can be locked in a fault at any time and can not continue welding, the normal operation requirement of the machine set can not be met, the operation and maintenance personnel are guided to reduce the operation speed of the machine set, the process section is properly adjusted, emergency measures are immediately adopted, and safety accidents and production accidents possibly caused by sudden faults or damage of the double-sliding-bell screw system are avoided.
The invention provides a high-stability double-sliding-bell-screw control system and a control method thereof, which improve a detection controllable structure, adopts an SIMATIC S7-400 programmable computer controller to design and manufacture a set of brand-new high-precision double-sliding-bell-screw component drive control system of a welding machine, and designs and adds a proportional valve group state detection feedback control link, a preposed pressure detection feedback, vibration detection feedback control link and a temperature detection feedback control link in the control system, and simultaneously designs a matching regulation control link matched with welding process requirements, thereby realizing the stable and long-acting use of the high-precision double-sliding-bell-screw component of the welding machine and the reliable and stable control of welding quality. The problems that the speed setting of the double-sliding-bell-screw component of the welding machine cannot be adjusted in real time according to the change condition of the transmission state of the welding machine in the control mode of the original high-precision double-sliding-bell-screw component drive control system of the welding machine, an effective matching adjustment method is not available, the drive control reliability of the high-precision double-sliding-bell-screw component of the welding machine is low, the fault rate is high, the welding is unstable, the drive control fault is easy to occur, the double-sliding-bell-screw component of the welding machine is lack of targeted protection and optimized maintenance measures, the degradation and even sudden damage are easy, the welding seam quality is influenced.
Drawings
FIG. 1 is a block diagram of a prior art dual ballscrew control system;
FIG. 2 is a block diagram of the dual ballscrew control system of the present invention.
Detailed Description
The technical scheme of the invention is further explained by combining the drawings and the embodiment.
Referring to fig. 2, the high-stability dual-sliding bell screw control system provided by the present invention includes a
The system speed setting module outputs a set value of 10mpm (10V), the set value is sent to the
Preferably, the
Meanwhile, a
Preferably, the
Preferably, the
The invention also provides a high-stability double-ring lead screw control method, which comprises the following steps:
the proportional valve group is improved, actual pressure detection output by two sides of the proportional valve group is increased, and state signals of the body of the proportional valve group are fed back to the control unit, so that effective monitoring of zero drift output of the proportional valve group and timely early warning and feedback adjustment of influence of state change of the body on a driving system are realized.
Outputting zero drift detection and adjustment treatment through a proportional valve group:
the comprehensive detection and analysis of three variables of position (encoder value), temperature and vibration, the deterioration to the damage of the double-sliding-bell screw driving system can be clearly shown on the three variables, the running state of the driving system can be accurately mastered by monitoring the three variables in real time and carrying out comparative analysis with a set model, the driving system is adjusted according to model setting when abnormal, the trend of the driving system from deterioration to damage caused by abnormality can be effectively reduced, meanwhile, the guiding and coping can be timely reminded, sudden damage can be avoided after matching coping measures are taken, and the use stability of the double-sliding-bell screw driving system is improved.
By encoder position detection and pre-adjustment:
temperature detection and pre-adjustment through a temperature detector:
vibration detection and pre-adjustment through a vibration detector:
preferably, the
The method for guiding the operation and maintenance personnel to perform accurate handling comprises the following specific steps:
when the preset processing unit lowers the speed by less than or equal to 5%, information is transmitted to the HMI to prompt operation and maintenance personnel to lower the speed specifically due to one or more factors of vibration, temperature, hysteresis or zero drift, and the operation and maintenance personnel are guided to carry out targeted inspection and maintenance on relevant parts of the driving system, such as oil supplementing maintenance and conventional online inspection, cleaning and fastening maintenance on relevant mechanisms of the double-sliding-bell screw rod.
When the preset processing unit reduces the speed setting by more than 5% and less than or equal to 10%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are warned, and the relative mechanisms of the double-sliding-bell screw are obviously degraded, so that the operation and maintenance personnel are guided to disassemble, inspect and maintain the double-sliding-bell screw, the hydraulic motor and the mechanical transmission structure on the basis of oil supplement, cleaning and fastening, namely the maintenance such as gap adjustment and the like must be disassembled and inspected in the next overhaul downtime.
When the preset processing unit reduces the speed setting by more than 10% and less than or equal to 20%, information is transmitted to an HMI (human machine interface), operation and maintenance personnel are warned, the double-sliding-bell screw system is seriously degraded, obvious fault points exist, the operation and maintenance personnel are guided to check the fault points in the next maintenance downtime, a fault point prompt list is listed, obvious fault parts such as a double-sliding-bell screw or a bearing on a mechanical structure are replaced, if the maintenance scheduled downtime date exceeds 7 days, the maintenance personnel are recommended to coordinate a production party to implement shutdown and maintenance in advance, and complete damage accidents caused by further degradation are avoided.
When the preset processing unit reduces the speed set by more than 20%, information is transmitted to the HMI, operation and maintenance personnel are seriously warned, the double-sliding-bell screw system of the welding machine can be locked in a fault at any time and can not continue welding, the normal operation requirement of the machine set can not be met, the operation and maintenance personnel are guided to reduce the operation speed of the machine set, the process section is properly adjusted, emergency measures are immediately adopted, and safety accidents and production accidents possibly caused by sudden faults or damage of the double-sliding-bell screw system are avoided.
In conclusion, the double-sliding-bell-screw control system and the control method thereof are applied to the double-sliding-bell-screw control drive control system of the cold-rolling double-cold-unit laser welding machine, the problem that the high-precision double-sliding-bell-screw component of the welding machine is suddenly degraded and damaged frequently in the past of the laser welding machine is solved, the problem that the speed setting of the high-precision double-sliding-bell-screw component of the welding machine cannot be adjusted in real time according to the change situation of the transmission state of the welding machine due to the fact that the control mode of the drive control system cannot be adjusted effectively, and the high-precision double-sliding-bell-screw component of the welding machine is low in drive control reliability, high in failure rate, unstable in welding and prone to drive control failure is solved.
It should be understood by those skilled in the art that the above embodiments are only for illustrating the present invention and are not to be used as a limitation of the present invention, and that changes and modifications to the above described embodiments are within the scope of the claims of the present invention as long as they are within the spirit and scope of the present invention.
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