CN110155437B - Brick tea packaging line control system and parameterization control method - Google Patents
Brick tea packaging line control system and parameterization control method Download PDFInfo
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- CN110155437B CN110155437B CN201910490708.2A CN201910490708A CN110155437B CN 110155437 B CN110155437 B CN 110155437B CN 201910490708 A CN201910490708 A CN 201910490708A CN 110155437 B CN110155437 B CN 110155437B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B25/00—Packaging other articles presenting special problems
- B65B25/02—Packaging agricultural or horticultural products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
- B65B35/30—Arranging and feeding articles in groups
- B65B35/36—Arranging and feeding articles in groups by grippers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
- B65B35/30—Arranging and feeding articles in groups
- B65B35/40—Arranging and feeding articles in groups by reciprocating or oscillatory pushers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
- B65B35/30—Arranging and feeding articles in groups
- B65B35/44—Arranging and feeding articles in groups by endless belts or chains
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B57/00—Automatic control, checking, warning, or safety devices
- B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
- B65B57/14—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged and operating to control, or stop, the feed of articles or material to be packaged
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Agronomy & Crop Science (AREA)
- Basic Packing Technique (AREA)
Abstract
The invention discloses a brick tea packaging line control system and a parameterization control method. The system comprises a master control system, a slave control system and a feeding, transporting and boxing control system, wherein a controller of the master control system is connected with a local HMI (human machine interface) on one hand and is connected with a controller of the slave control system through a communication expansion module on the other hand; the feed transport and bin control system is a separate subsystem. The method comprises the following steps: the main control system carries out a parameter initialization program, a self-detection program, a mode selection program, a reset program, a multi-motor cooperative control program and a fault diagnosis and fault processing program; carrying out debugging operation of control parameters and a control system from a control system program; the feed delivery and binning control system program performs the feed delivery program and binning algorithm program operations. The invention can pack and case brick tea with different sizes, realizes different position and speed control, and improves the adaptability and safety of the control system and the automation degree of the production line.
Description
Technical Field
The invention relates to the field of industrial automation control, in particular to a brick tea packaging line control system and a parameterization control method.
Background
Brick tea, namely pressing tea leaves into a shape the same as that of a brick; at present, similar brick tea packaging technologies are mature, such as packaging of A4 paper and packaging technologies of small boxes, but due to the difference of brick tea packaging technologies, the technologies cannot be directly applied to brick tea packaging, and most brick tea enterprises still adopt manual packaging.
The sizes of brick tea are diversified, which puts higher requirements on the adaptability of brick tea packaging equipment, and the current market lacks packaging equipment capable of adapting to brick tea with different sizes and a corresponding control method.
Disclosure of Invention
The invention aims to provide a brick tea packaging line control system and a parameterization control method, which can package and pack brick tea with different sizes, and have strong adaptability, high safety and high automation degree.
The technical solution for realizing the purpose of the invention is as follows: a brick tea packaging line control system comprises a power supply circuit, a master control system, a slave control system, a feeding, transporting and boxing control system, a first sensor system and a second sensor system;
the power supply circuit comprises a control circuit, an air switch, a leakage protection device, a filter and a switch power supply and is used for supplying power to the whole control system;
the main control system comprises a first HMI, a main PLC, a communication expansion module, an alarm device, a first servo driver group, a first servo motor group, a first servo electric cylinder group and a first electromagnetic valve;
the slave control system comprises a slave PLC controller, a communication expansion module, a stepping driver group, a stepping motor group, a servo third electric cylinder, a second servo driver group and a servo fifth motor;
the feeding, conveying and boxing control system comprises a third PLC, an alarm device, a second HMI, a third servo driver group, a three-degree-of-freedom manipulator, an electromagnetic valve group, a frequency converter and a variable frequency motor;
the first sensor system comprises a screw rod position sensor, a material sensor, a cylinder position sensor, a ball contact type sensor and a servo electric cylinder position sensor and is used for carrying out logic control on a master control system and a slave control system;
the second sensor system comprises a screw rod position sensor, a material sensor and a cylinder position sensor and is used for carrying out logic control on the feeding conveying and boxing control system;
a main control system program is arranged in the main PLC;
a slave control system program is arranged in the slave PLC;
and a feeding conveying and boxing control program is arranged in the third PLC.
Further, the main control system comprises a first HMI, a main PLC controller, a communication expansion module, an alarm device, a first servo driver group, a first servo motor group, and a first electromagnetic valve, and specifically comprises the following components:
the first HMI is used for setting control parameters of the master control system and the slave control system, displaying alarm information and package data, switching control modes and debugging the master control system and the slave control system;
the master PLC controller is a control core of a master control system and a slave control system;
the communication expansion module is used for communicating with the slave controller;
the first servo driver group receives a control signal of the main PLC, controls the first servo motor group and the first servo electric cylinder group and feeds back servo alarm information to the main PLC;
the first servo motor set comprises a servo first motor, a servo second motor, a servo third motor and a servo fourth motor; the servo first motor is used for controlling the transverse movement of the paper taking transverse moving screw rod assembly, and the paper taking transverse moving screw rod assembly drives the paper taking lifting screw rod assembly to transversely move; the servo second motor is used for controlling the lifting motion of the paper taking lifting screw rod assembly; the servo third motor is used for controlling the transverse movement of the brick taking transverse moving screw rod assembly, and the brick taking transverse moving screw rod assembly drives the brick taking lifting screw rod assembly to transversely move; the servo fourth motor is used for controlling the lifting motion of the brick taking lifting screw rod assembly;
the first servo electric cylinder group comprises a servo first electric cylinder and a servo second electric cylinder and is used for controlling the left paper folding mechanism and the right paper folding mechanism;
the first electromagnetic valve is a three-position five-way valve and is used for controlling the stroke of the first air cylinder, so that the opening degree of the first material taking mechanical arm is controlled, and the brick tea of different sizes can be grabbed.
Further, the slave control system comprises a slave PLC controller, a communication expansion module, a stepping driver set, a stepping motor set, a third servo electric cylinder, a second servo driver set and a fifth servo motor, and specifically comprises the following components:
the second servo driver group receives a control signal of the slave PLC, controls the servo fifth motor and the servo third electric cylinder and feeds back servo alarm information to the slave PLC;
the stepping motor set comprises a stepping first motor and a stepping second motor, the stepping first motor controls the lifting of the first lifting platform, and the stepping second motor is used for controlling the lifting of the second lifting platform;
the servo fifth motor is used for controlling the lifting of the paper short-edge dispensing screw rod assembly;
and the servo third electric cylinder is used for pushing the packaged brick tea out of the packaging station.
Further, the feeding, conveying and boxing control system comprises a third PLC controller, an alarm device, a second HMI, a third servo driver group, a three-degree-of-freedom manipulator, an electromagnetic valve group, a frequency converter and a variable frequency motor, and the feeding, conveying and boxing control system specifically comprises the following components:
the third PLC controller adopts an independent controller, is not connected with other PLC controllers in the whole control system, and is used as a control core of the feeding conveying and boxing control system;
the second HMI is used for setting control parameters of the feeding conveying and boxing control system, displaying alarm information and boxing data, switching control modes and debugging the feeding conveying and boxing control system;
the third servo driver group receives a control signal of a third PLC controller, realizes control over a third servo motor group and feeds alarm information back to the third PLC;
the three-degree-of-freedom manipulator comprises a third servo motor set, an X-axis screw rod assembly, a Y-axis screw rod assembly, a Z-axis screw rod assembly, a second cylinder and a second material taking manipulator, wherein the third servo motor set comprises a servo sixth motor, a servo seventh motor and a servo eighth motor; the servo sixth motor is used for controlling the movement of the X-axis lead screw component and further controlling the movement of the Y-axis lead screw component on the X axis; the servo seventh motor is used for controlling the motion of the Y-axis lead screw component and further controlling the motion of the Z-axis lead screw component on the Y axis; the servo eighth motor is used for controlling the movement of the Z-axis screw rod component so as to control the movement of the second material taking mechanical arm on the Z axis;
the frequency converter is used for driving the variable frequency motor so as to control the feeding conveyor belt, and is matched with the material sensor to realize fixed-point control on the material;
the electromagnetic valve group comprises a second electromagnetic valve and a third electromagnetic valve; the second electromagnetic valve is a three-position five-way valve and is used for controlling the stroke of the second cylinder and further controlling the opening of the second material taking manipulator, so that the brick tea of different sizes can be grabbed; the third electromagnetic valve is a two-position five-way valve and is used for controlling the brick pushing action of the third cylinder and pushing the brick tea at the appointed position on the conveyor belt to the material taking station of the first material taking manipulator;
the alarm device comprises a warning lamp and a buzzer; the warning light has three colors of red, yellow and green, and the faults of different degrees are alarmed by controlling the warning light with different colors and the buzzer.
Further, the system control program comprises a master control system program, a slave control system program and a feeding, conveying and boxing control system program, and the system control program comprises the following specific steps:
the main control system program comprises a parameter initialization program, a self-detection program, a mode selection program, a reset program, a multi-motor cooperative control program and a fault diagnosis and fault processing program;
the parameter initialization program is used for initializing the speed and the position of each servo motor, inputting a lead screw lead, a distance that the lead screw needs to move, the number of pulses required by each rotation of the servo motor, pulse frequency and the parameter initialization program on the first HMI, and calculating the movement pulse quantity and the movement speed of the servo motor;
the self-detection program is used for carrying out automatic detection during starting and detecting whether all control objects of each controller are at the original point, if the control objects are not at the original point, the self-detection program automatically calls the reset program to reset all the control objects, and if the control objects still do not return to the original point after the reset program is executed, the self-detection program gives an alarm;
the reset program is used for orderly resetting all control objects of each controller;
the mode selection program comprises an automatic control program, a jog control program and a manual control program; when the control system is debugged, firstly calling a point control program to perform test operation and sensor positioning on each control object, and calling a reset program to reset each control object to the original point if all the control objects can normally operate; the manual control program is used for checking whether the automatic control program is correct, the automatic control program is decomposed and then executed in a single step, if the expected effect can be achieved, the automatic control program is correct, and the automatic program can be switched to an automatic program running mode after reset;
the multi-motor cooperative control program is used for performing cooperative control of the motors controlled by the controllers;
the fault diagnosis and processing program is used for detecting and processing faults generated by the control system, the fault processing program carries out different processing according to different detected fault types, and the alarm device is started to alarm while the fault is displayed through the first HMI;
the program architecture of the slave control system program is the same as that of the master control system program, control parameters required by the slave control system and debugging of the control system are operated through a first HMI of the master control system, and alarm information of the slave control system is displayed on the first HMI of the master control system;
the program of the feeding conveying and boxing control system is the same as the program structure of the main control system, and the feeding conveying and boxing control system program comprises a feeding conveying program and a boxing algorithm program;
the feeding and conveying program is used for conveying the brick tea at fixed points, and different speed control of the material conveying conveyor belt is realized by changing the frequency of the frequency converter;
the boxing algorithm program is used for planning a boxing path of the brick tea, inputting the length, the width and the height of the brick tea and the length, the width and the height of a box on the second HMI, calculating the number of the brick tea blocks which can be stored in the current box, the number of the brick tea blocks which can be stored in the current box and position information which needs to be stored in the current box by the boxing algorithm program, and feeding the calculated information back to the multi-motor cooperative control program, so that the brick tea can be stored at a fixed point.
Furthermore, the three-degree-of-freedom manipulator in the feeding, conveying and boxing control system adopts redundancy control, and the three-degree-of-freedom manipulator can be reduced into a two-degree-of-freedom manipulator or a one-degree-of-freedom manipulator for use by changing parameters.
A parameterized control method of a brick tea packaging line control system comprises the following steps:
step 1, a main control system carries out parameterization control;
step 2, carrying out parameterization control on the slave control system;
and 3, carrying out parameterization control on the feeding, transporting and boxing control system.
Further, the main control system in step 1 performs parameterized control, specifically as follows:
step 1.1, electrifying the whole control system, and initializing parameters by a main controller;
step 1.2, a controller of the main system executes a self-checking program, and if an execution mechanism is not at the original point, a reset program is automatically executed for resetting; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
step 1.3, after the main control system is reset, if the parameters do not need to be updated, directly selecting a control mode, and then waiting for the signal of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the main control system from the first HMI, switching to a manual mode for single step debugging, and switching to an automatic control mode if an expected result is achieved and the parameter calculation is correct; otherwise, the parameters are recalculated until the result is correct;
step 1.4, when the main control system is in an automatic mode, if a material loading material sensor has a signal, the main control system performs an automatic packaging process and performs alarm detection, and if an alarm is generated, the main control system automatically stops and alarms according to the alarm type; in the automatic control mode, reset or stop operation can be performed;
and 1.5, repeating the step 1.4 until the parameterization control is finished.
Further, the slave control system in step 2 performs parameterized control, specifically as follows:
step 2.1, electrifying the whole control system, and initializing parameters from the controller;
2.2, a controller of the slave system executes a self-checking program, and if an execution mechanism is not at the original point, a reset program is automatically executed for resetting; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
step 2.3, after the slave control systems are reset, if parameters do not need to be updated, directly selecting a control mode, and then waiting for signals of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the slave control system from the first HMI, switching to a manual mode for single step debugging, and switching to an automatic control mode if an expected result is achieved and the parameter calculation is correct; otherwise, the parameters are recalculated until the result is correct;
step 2.4, when the slave control system is in an automatic mode, if the feeding material sensor has a signal, the slave control system performs an automatic packaging process and performs alarm detection, and if an alarm is generated, the slave control system automatically stops and alarms according to the alarm type; in the automatic control mode, reset or stop operation can be carried out;
and 2.5, repeating the step 2.4 until the parameterization control is finished.
Further, the feeding, transporting and boxing control system in the step 3 performs parametric control, which specifically comprises the following steps:
step 3.1, electrifying the whole control system, and initializing parameters by using a third PLC;
3.2, executing a self-checking program by the third PLC, and if the execution mechanism is not at the original point, automatically executing a resetting program to reset; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
3.3, after the resetting is finished, if the parameters do not need to be updated, directly selecting a control mode, and then waiting for the signal of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the feeding conveying and boxing control system from the second HMI, switching to a manual mode for single step debugging, if the expected results can be achieved, indicating that the parameter calculation is correct, switching to an automatic control mode, and if the expected results can be achieved, recalculating the parameters until the results are correct;
3.4, when the feeding conveying and boxing control system is in an automatic mode, if a signal is sent by the feeding material sensor, the control system performs an automatic boxing process and performs alarm detection, and if an alarm is generated, the feeding conveying and boxing control system automatically stops and alarms according to the alarm type; in the automatic control mode, the reset or stop operation can be carried out;
and 3.5, repeating the step 3.4 until the parameterization control is finished.
Compared with the prior art, the invention has the remarkable advantages that: (1) the brick tea is packaged and boxed in different sizes; (2) the control system is convenient to debug, and a parameterized control method is used, so that the adaptability of the control system is enhanced, the automation degree and the safety of a brick tea packaging line are improved, and the working efficiency is improved; (3) the manpower is saved, and the production cost is reduced.
Drawings
FIG. 1 is a schematic block diagram of a brick tea packaging line control system of the present invention.
Fig. 2 is an overall program architecture diagram of the present invention.
FIG. 3 is a flow chart of the program control of the master and slave control systems of the control system in the parameterized control method of the brick tea wrap control system of the present invention.
FIG. 4 is a flow chart of the program control of the feed transport and bin packing control system in the process of the present invention.
Detailed Description
The invention is described in further detail below with reference to the figures and the embodiments.
With reference to fig. 1, the brick tea packaging line control system of the present invention comprises a power circuit, a master control system, a slave control system, a feeding, transporting and boxing control system, a first sensor system and a second sensor system;
the power supply circuit comprises a control circuit, an air switch, a leakage protection device, a filter and a switch power supply and is used for supplying power to the whole control system.
The main control system comprises a first HMI, a main PLC, a communication expansion module, an alarm device, a first servo driver group, a first servo motor group, a first servo electric cylinder group and a first electromagnetic valve:
the first HMI is used for setting control parameters of the master control system and the slave control system, displaying alarm information and package data, switching control modes and debugging the master control system and the slave control system;
the master PLC controller is a control core of a master control system and a slave control system;
the communication expansion module is used for communicating with the slave controller;
the first servo driver group receives a control signal of the main PLC, controls the first servo motor group and the first servo electric cylinder group and feeds back servo alarm information to the main PLC;
the first servo motor set comprises a servo first motor, a servo second motor, a servo third motor and a servo fourth motor; the servo first motor is used for controlling the transverse movement of the paper taking transverse moving screw rod assembly, and the paper taking transverse moving screw rod assembly drives the paper taking lifting screw rod assembly to transversely move; the servo second motor is used for controlling the lifting motion of the paper taking lifting screw rod assembly; the servo third motor is used for controlling the transverse movement of the brick taking transverse moving screw rod assembly, and the brick taking transverse moving screw rod assembly drives the brick taking lifting screw rod assembly to transversely move; the servo fourth motor is used for controlling the lifting motion of the brick taking lifting screw rod assembly;
the first servo electric cylinder group comprises a servo first electric cylinder and a servo second electric cylinder and is used for controlling the left paper folding mechanism and the right paper folding mechanism;
the first electromagnetic valve is a three-position five-way valve and is used for controlling the stroke of the first air cylinder, so that the opening degree of the first material taking mechanical arm is controlled, and the brick tea of different sizes can be grabbed.
The slave control system comprises a slave PLC controller, a communication expansion module, a stepping driver set, a stepping motor set, a servo third electric cylinder, a second servo driver set and a servo fifth motor:
the second servo driver group receives a control signal of the slave PLC, controls the servo fifth motor and the servo third electric cylinder and feeds back servo alarm information to the slave PLC;
the stepping motor set comprises a stepping first motor and a stepping second motor, the stepping first motor controls the lifting of the first lifting platform, and the stepping second motor is used for controlling the lifting of the second lifting platform;
the servo fifth motor is used for controlling the lifting of the paper short-edge dispensing screw rod assembly;
and the servo third electric cylinder is used for pushing the packaged brick tea out of the packaging station.
The feeding, conveying and boxing control system comprises a third PLC, an alarm device, a second HMI, a third servo driver group, a three-degree-of-freedom manipulator, an electromagnetic valve group, a frequency converter and a variable frequency motor:
the third PLC controller adopts an independent controller, is not connected with other PLC controllers in the whole control system, and is used as a control core of the feeding conveying and boxing control system;
the second HMI is used for setting control parameters of the feeding conveying and boxing control system, displaying alarm information and boxing data, switching control modes and debugging the feeding conveying and boxing control system;
the third servo driver group receives a control signal of a third PLC controller, realizes control over a third servo motor group and feeds alarm information back to the third PLC;
the three-degree-of-freedom manipulator comprises a third servo motor set, an X-axis screw rod assembly, a Y-axis screw rod assembly, a Z-axis screw rod assembly, a second cylinder and a second material taking manipulator, wherein the third servo motor set comprises a servo sixth motor, a servo seventh motor and a servo eighth motor; the servo sixth motor is used for controlling the movement of the X-axis lead screw component and further controlling the movement of the Y-axis lead screw component on the X axis; the servo seventh motor is used for controlling the motion of the Y-axis lead screw component and further controlling the motion of the Z-axis lead screw component on the Y axis; the servo eighth motor is used for controlling the movement of the Z-axis screw rod component so as to control the movement of the second material taking mechanical arm on the Z axis;
the frequency converter is used for driving the variable frequency motor so as to control the feeding conveyor belt, and is matched with the material sensor to realize fixed-point control on the material;
the electromagnetic valve group comprises a second electromagnetic valve and a third electromagnetic valve; the second electromagnetic valve is a three-position five-way valve and is used for controlling the stroke of the second cylinder and further controlling the opening of the second material taking manipulator, so that the brick tea of different sizes can be grabbed; the third electromagnetic valve is a two-position five-way valve and is used for controlling the brick pushing action of the third cylinder and pushing the brick tea at the appointed position on the conveyor belt to the material taking station of the first material taking manipulator;
the alarm device comprises a warning lamp and a buzzer; the warning light has three colors of red, yellow and green, and the faults of different degrees are alarmed by controlling the warning light with different colors and the buzzer.
The first sensor system comprises a screw rod position sensor, a material sensor, a cylinder position sensor, a ball contact sensor and a servo electric cylinder position sensor and is used for carrying out logic control on a master control system and a slave control system.
The second sensor system comprises a screw rod position sensor, a material sensor and a cylinder position sensor and is used for carrying out logic control on the feeding conveying and boxing control system.
With reference to fig. 2, a master control system program is provided in the master PLC controller, a slave control system program is provided in the slave PLC controller, and a feeding conveying and boxing control program is provided in the third PLC controller:
the main control system program comprises a parameter initialization program, a self-detection program, a mode selection program, a reset program, a multi-motor cooperative control program and a fault diagnosis and fault processing program;
the parameter initialization program is used for initializing the speed and the position of each servo motor, inputting a lead screw lead, a distance that the lead screw needs to move, the number of pulses required by each rotation of the servo motor, pulse frequency and the parameter initialization program on the first HMI, and calculating the movement pulse quantity and the movement speed of the servo motor;
the self-detection program is used for carrying out automatic detection during starting and detecting whether all control objects of each controller are at the original point, if the control objects are not at the original point, the self-detection program automatically calls the reset program to reset all the control objects, and if the control objects still do not return to the original point after the reset program is executed, the self-detection program gives an alarm;
the reset program is used for resetting all control objects of each controller accurately and orderly;
the mode selection program comprises an automatic control program, a jog control program and a manual control program; when the control system is debugged, firstly calling a point control program to perform test operation and sensor positioning on each control object, and calling a reset program to reset each control object to the original point if all the control objects can normally operate; the manual control program is used for checking whether the automatic control program is correct, the automatic control program is decomposed and then executed in a single step, if the expected effect can be achieved, the automatic control program is correct, and the automatic program can be switched to an automatic program running mode after reset;
the multi-motor cooperative control program is used for performing cooperative control of the motors controlled by the controllers;
the fault diagnosis and processing program is used for detecting and processing faults generated by the control system, the fault processing program carries out different processing according to different detected fault types, and the alarm device is started to alarm while the fault is displayed through the first HMI;
the program architecture of the slave control system program is the same as that of the master control system program, control parameters required by the slave control system and debugging of the control system are operated through a first HMI of the master control system, and alarm information of the slave control system is displayed on the first HMI of the master control system;
the program of the feeding conveying and boxing control system is the same as the program structure of the main control system, and the feeding conveying and boxing control system program comprises a feeding conveying program and a boxing algorithm program;
the feeding and conveying program is used for conveying the brick tea at fixed points, and different speed control of the material conveying conveyor belt is realized by changing the frequency of the frequency converter;
the boxing algorithm program is used for planning a boxing path of the brick tea, inputting the length, the width and the height of the brick tea and the length, the width and the height of a box on the second HMI, calculating the number of the brick tea blocks which can be stored in the current box, the number of the brick tea blocks which can be stored in the current box and position information which needs to be stored in the current box by the boxing algorithm program, and feeding the calculated information back to the multi-motor cooperative control program, so that the brick tea can be stored at a fixed point.
Further, the first HMI is communicated with the master PLC controller through RS232, and the master PLC controller is connected with the slave PLC controller through a communication expansion module; and the master control system and the slave control system are in indirect communication through a link relay and a link data register in the shared PLC.
Furthermore, the master PLC controller, the slave PLC controller and the third PLC controller are all loose PLC controllers.
Furthermore, the paper taking transverse moving screw rod assembly, the paper taking lifting screw rod assembly, the brick taking transverse moving screw rod assembly, the brick taking lifting screw rod assembly, the servo first electric cylinder, the servo second electric cylinder and the servo third electric cylinder are respectively provided with two limit inductors and an original point inductor, and the first lifting platform and the second lifting platform are respectively provided with an original point inductor and an upper limit inductor; the limit sensor is used for safety protection, and the origin sensor is used for logic control in an automatic control mode.
Furthermore, the descending displacement of the paper taking lifting screw rod assembly is determined according to the data of the ball contact type sensor, and the position control of other screw rod assemblies and the electric cylinder is determined according to the parameters.
Furthermore, the three-degree-of-freedom manipulator in the feeding, conveying and boxing control system adopts redundancy control, and the three-degree-of-freedom manipulator can be reduced into a two-degree-of-freedom manipulator or a one-degree-of-freedom manipulator for use by changing parameters.
With reference to fig. 3 and 4, a parameterized control method of a brick tea packaging line control system comprises the following steps:
step 1, the main control system carries out parameterization control:
step 1.1, electrifying the whole control system, and initializing parameters by a main controller;
step 1.2, a controller of the main system executes a self-checking program, and if an execution mechanism is not at the original point, a reset program is automatically executed for resetting; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
step 1.3, after the main control system is reset, if the parameters do not need to be updated, directly selecting a control mode, and then waiting for the signal of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the main control system from the first HMI, switching to a manual mode for single step debugging, and switching to an automatic control mode if an expected result is achieved and the parameter calculation is correct; otherwise, the parameters are recalculated until the result is correct;
step 1.4, when the main control system is in an automatic mode, if a material loading material sensor has a signal, the main control system performs an automatic packaging process and performs alarm detection, and if an alarm is generated, the main control system automatically stops and alarms according to the alarm type; in the automatic control mode, reset or stop operation can be carried out;
and 1.5, repeating the step 1.4 until the parameterization control is finished.
Step 2, carrying out parameterization control on the slave control system:
step 2.1, electrifying the whole control system, and initializing parameters from the controller;
2.2, a controller of the slave system executes a self-checking program, and if an execution mechanism is not at the original point, a reset program is automatically executed for resetting; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
step 2.3, after the slave control systems are reset, if parameters do not need to be updated, directly selecting a control mode, and then waiting for signals of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the slave control system from the first HMI, switching to a manual mode for single step debugging, and switching to an automatic control mode if an expected result is achieved and the parameter calculation is correct; otherwise, the parameters are recalculated until the result is correct;
step 2.4, when the slave control system is in an automatic mode, if the feeding material sensor has a signal, the slave control system performs an automatic packaging process and performs alarm detection, and if an alarm is generated, the slave control system automatically stops and alarms according to the alarm type; in the automatic control mode, reset or stop operation can be carried out;
and 2.5, repeating the step 2.4 until the parameterization control is finished.
Step 3, carrying out parameterization control on the feeding, transporting and boxing control system:
step 3.1, electrifying the whole control system, and initializing parameters by using a third PLC;
3.2, executing a self-checking program by the third PLC, and if the execution mechanism is not at the original point, automatically executing a resetting program to reset; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
3.3, after the resetting is finished, if the parameters do not need to be updated, directly selecting a control mode, and then waiting for the signal of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the feeding conveying and boxing control system from the second HMI, switching to a manual mode for single step debugging, if the expected results can be achieved, indicating that the parameter calculation is correct, switching to an automatic control mode, and if the expected results can be achieved, recalculating the parameters until the results are correct;
3.4, when the feeding conveying and boxing control system is in an automatic mode, if a signal is sent by the feeding material sensor, the control system performs an automatic boxing process and performs alarm detection, and if an alarm is generated, the feeding conveying and boxing control system automatically stops and alarms according to the alarm type; in the automatic control mode, the reset or stop operation can be carried out;
and 3.5, repeating the step 3.4 until the parameterization control is finished.
In conclusion, the brick tea packaging machine realizes the packaging and boxing of brick tea with different sizes; and the control system is convenient to debug, and a parameterized control method is used, so that the adaptability of the control system is enhanced, the automation degree and the safety of a brick tea packaging line are improved, the labor is saved, the production cost is reduced, and the working efficiency is improved.
Claims (8)
1. A brick tea packaging line control system is characterized by comprising a power supply circuit, a master control system, a slave control system, a feeding, transporting and boxing control system, a first sensor system and a second sensor system;
the power supply circuit comprises a control circuit, an air switch, a leakage protection device, a filter and a switch power supply and is used for supplying power to the whole control system;
the main control system comprises a first HMI, a main PLC, a communication expansion module, an alarm device, a first servo driver group, a first servo motor group, a first servo electric cylinder group and a first electromagnetic valve;
the slave control system comprises a slave PLC controller, a communication expansion module, a stepping driver group, a stepping motor group, a servo third electric cylinder, a second servo driver group and a servo fifth motor;
the feeding, transporting and boxing control system comprises a third PLC, an alarm device, a second HMI, a third servo driver group, a three-degree-of-freedom manipulator, an electromagnetic valve group, a frequency converter and a variable frequency motor;
the first sensor system comprises a screw rod position sensor, a material sensor, a cylinder position sensor, a ball contact type sensor and a servo electric cylinder position sensor and is used for carrying out logic control on a master control system and a slave control system;
the second sensor system comprises a screw rod position sensor, a material sensor and a cylinder position sensor and is used for carrying out logic control on the feeding, transporting and boxing control system;
a main control system program is arranged in the main PLC;
a slave control system program is arranged in the slave PLC;
a feeding conveying and boxing control program is arranged in the third PLC;
the main control system comprises a first HMI, a main PLC, a communication expansion module, an alarm device, a first servo driver group, a first servo motor group, a first servo electric cylinder group and a first electromagnetic valve, and specifically comprises the following components:
the first HMI is used for setting control parameters of the master control system and the slave control system, displaying alarm information and package data, switching control modes and debugging the master control system and the slave control system;
the master PLC controller is a control core of a master control system and a slave control system;
the communication expansion module is used for communicating with the slave controller;
the first servo driver group receives a control signal of the main PLC, controls the first servo motor group and the first servo electric cylinder group and feeds back servo alarm information to the main PLC;
the first servo motor set comprises a servo first motor, a servo second motor, a servo third motor and a servo fourth motor; the servo first motor is used for controlling the transverse movement of the paper taking transverse moving screw rod assembly, and the paper taking transverse moving screw rod assembly drives the paper taking lifting screw rod assembly to transversely move; the servo second motor is used for controlling the lifting motion of the paper taking lifting screw rod assembly; the servo third motor is used for controlling the transverse movement of the brick taking transverse moving screw rod assembly, and the brick taking transverse moving screw rod assembly drives the brick taking lifting screw rod assembly to transversely move; the servo fourth motor is used for controlling the lifting motion of the brick taking lifting screw rod assembly;
the first servo electric cylinder group comprises a servo first electric cylinder and a servo second electric cylinder and is used for controlling the left paper folding mechanism and the right paper folding mechanism;
the first electromagnetic valve is a three-position five-way valve and is used for controlling the stroke of the first air cylinder, so that the opening degree of the first material taking mechanical arm is controlled, and the brick tea of different sizes can be grabbed.
2. The brick tea packaging line control system according to claim 1, wherein the slave control system comprises a slave PLC controller, a communication expansion module, a stepping driver set, a stepping motor set, a servo third electric cylinder, a second servo driver set and a servo fifth electric motor, and the slave control system comprises the following components:
the second servo driver group receives a control signal of the slave PLC, controls the servo fifth motor and the servo third electric cylinder and feeds back servo alarm information to the slave PLC;
the stepping motor set comprises a stepping first motor and a stepping second motor, the stepping first motor controls the lifting of the first lifting platform, and the stepping second motor is used for controlling the lifting of the second lifting platform;
the servo fifth motor is used for controlling the lifting of the paper short-edge dispensing screw rod assembly;
and the servo third electric cylinder is used for pushing the packaged brick tea out of the packaging station.
3. The brick tea packaging line control system of claim 1, wherein the feeding, transporting and boxing control system comprises a third PLC controller, an alarm device, a second HMI, a third servo driver group, a three-degree-of-freedom manipulator, an electromagnetic valve group, a frequency converter and a variable frequency motor, and the control system comprises the following components:
the third PLC controller adopts an independent controller, is not connected with other PLC controllers in the whole control system, and is used as a control core of the feeding, transporting and boxing control system;
the second HMI is used for setting control parameters of the feeding transportation and boxing control system, displaying alarm information and boxing data, switching control modes and debugging the feeding transportation and boxing control system;
the third servo driver group receives a control signal of a third PLC controller, realizes control over a third servo motor group and feeds alarm information back to the third PLC;
the three-degree-of-freedom manipulator comprises a third servo motor set, an X-axis screw rod assembly, a Y-axis screw rod assembly, a Z-axis screw rod assembly, a second cylinder and a second material taking manipulator, wherein the third servo motor set comprises a servo sixth motor, a servo seventh motor and a servo eighth motor; the servo sixth motor is used for controlling the movement of the X-axis lead screw component and further controlling the movement of the Y-axis lead screw component on the X axis; the servo seventh motor is used for controlling the motion of the Y-axis lead screw component and further controlling the motion of the Z-axis lead screw component on the Y axis; the servo eighth motor is used for controlling the movement of the Z-axis screw rod component so as to control the movement of the second material taking mechanical arm on the Z axis;
the frequency converter is used for driving the variable frequency motor so as to control the feeding conveyor belt, and is matched with the material sensor to realize fixed-point control on the material;
the electromagnetic valve group comprises a second electromagnetic valve and a third electromagnetic valve; the second electromagnetic valve is a three-position five-way valve and is used for controlling the stroke of the second cylinder and further controlling the opening of the second material taking manipulator, so that the brick tea of different sizes can be grabbed; the third electromagnetic valve is a two-position five-way valve and is used for controlling the brick pushing action of the third cylinder and pushing the brick tea at the appointed position on the conveyor belt to the material taking station of the first material taking manipulator;
the alarm device comprises a warning lamp and a buzzer; the warning light has three colors of red, yellow and green, and the faults of different degrees are alarmed by controlling the warning light with different colors and the buzzer.
4. The brick tea packaging line control system of claim 1, wherein the control programs of the system include a master control system program, a slave control system program and a feed transport and encasement control system program, as follows:
the main control system program comprises a parameter initialization program, a self-detection program, a mode selection program, a reset program, a multi-motor cooperative control program and a fault diagnosis and fault processing program;
the parameter initialization program is used for initializing the speed and the position of each servo motor, inputting a lead screw lead, a distance that the lead screw needs to move, the number of pulses required by each rotation of the servo motor, pulse frequency and the parameter initialization program on the first HMI, and calculating the movement pulse quantity and the movement speed of the servo motor;
the self-detection program is used for carrying out automatic detection during starting and detecting whether all control objects of each controller are at the original point, if the control objects are not at the original point, the self-detection program automatically calls the reset program to reset all the control objects, and if the control objects still do not return to the original point after the reset program is executed, the self-detection program gives an alarm;
the reset program is used for orderly resetting all control objects of each controller;
the mode selection program comprises an automatic control program, a jog control program and a manual control program; when the control system is debugged, firstly calling a point control program to perform test operation and sensor positioning on each control object, and calling a reset program to reset each control object to the original point if all the control objects can normally operate; the manual control program is used for checking whether the automatic control program is correct, the automatic control program is decomposed and then executed in a single step, if the expected effect can be achieved, the automatic control program is correct, and the automatic program can be switched to an automatic program running mode after reset;
the multi-motor cooperative control program is used for performing cooperative control of the motors controlled by the controllers;
the fault diagnosis and processing program is used for detecting and processing faults generated by the control system, the fault processing program carries out different processing according to different detected fault types, and the alarm device is started to alarm while the fault is displayed through the first HMI;
the program architecture of the slave control system program is the same as that of the master control system program, control parameters required by the slave control system and debugging of the control system are operated through a first HMI of the master control system, and alarm information of the slave control system is displayed on the first HMI of the master control system;
the feed transportation and boxing control system program is the same as the program architecture of the main control system, and comprises a feed transportation program and a boxing algorithm program;
the feeding and conveying program is used for conveying the brick tea at fixed points, and different speed control of the material conveying conveyor belt is realized by changing the frequency of the frequency converter;
the boxing algorithm program is used for planning a boxing path of the brick tea, inputting the length, the width and the height of the brick tea and the length, the width and the height of a box on the second HMI, calculating the number of the brick tea blocks which can be stored in the current box, the number of the brick tea blocks which can be stored in the current box and position information which needs to be stored in the current box by the boxing algorithm program, and feeding the calculated information back to the multi-motor cooperative control program, so that the brick tea can be stored at a fixed point.
5. The brick tea packaging line control system of claim 1, wherein the three-degree-of-freedom robot in the feeding, transporting and boxing control system adopts redundant control, and the three-degree-of-freedom robot can be lowered to be used by a two-degree-of-freedom robot or a one-degree-of-freedom robot by changing parameters.
6. A parameterized control method of a brick tea packaging line control system is characterized by comprising the following steps:
step 1, a main control system carries out parameterization control;
step 2, carrying out parameterization control on the slave control system;
step 3, carrying out parameterization control on the feeding, transporting and boxing control system;
the main control system in step 1 performs parameterization control, specifically as follows:
step 1.1, electrifying the whole control system, and initializing parameters by a main controller;
step 1.2, a controller of the main system executes a self-checking program, and if an execution mechanism is not at the original point, a reset program is automatically executed for resetting; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
step 1.3, after the main control system is reset, if the parameters do not need to be updated, directly selecting a control mode, and then waiting for the signal of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the main control system from the first HMI, switching to a manual mode for single step debugging, and switching to an automatic control mode if an expected result is achieved and the parameter calculation is correct; otherwise, the parameters are recalculated until the result is correct;
step 1.4, when the main control system is in an automatic mode, if a material loading material sensor has a signal, the main control system performs an automatic packaging process and simultaneously performs alarm detection, and if an alarm is generated, the main control system automatically stops and alarms according to the alarm type; in the automatic control mode, reset or stop operation can be performed;
and 1.5, repeating the step 1.4 until the parameterization control is finished.
7. The parametric control method for a brick tea packaging line control system according to claim 6, wherein the slave control system of step 2 performs parametric control, specifically as follows:
step 2.1, electrifying the whole control system, and initializing parameters from the controller;
2.2, a controller of the slave system executes a self-checking program, and if an execution mechanism is not at the original point, a reset program is automatically executed for resetting; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
step 2.3, after the slave control systems are reset, if parameters do not need to be updated, directly selecting a control mode, and then waiting for signals of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the slave control system from the first HMI, switching to a manual mode for single step debugging, and switching to an automatic control mode if an expected result is achieved and the parameter calculation is correct; otherwise, the parameters are recalculated until the result is correct;
step 2.4, when the slave control system is in an automatic mode, if the feeding material sensor has a signal, the slave control system performs an automatic packaging process and simultaneously performs alarm detection, and if an alarm is generated, the slave control system automatically stops and alarms according to the alarm type; in the automatic control mode, reset or stop operation can be carried out;
and 2.5, repeating the step 2.4 until the parameterization control is finished.
8. The parametric control method for a brick tea packaging line control system as claimed in claim 6, wherein the feeding transportation and boxing control system of step 3 performs parametric control, specifically as follows:
step 3.1, electrifying the whole control system, and initializing parameters by using a third PLC;
3.2, the third PLC executes a self-checking program, and if the execution mechanism is not at the original point, the reset program is automatically executed for resetting; if the executing mechanism is still not at the original point after resetting, switching to a jog mode to return to the original point;
3.3, after the resetting is finished, if the parameters do not need to be updated, directly selecting a control mode, and then waiting for the signal of the feeding material sensor by the system; if the parameters need to be updated, updating the parameters of the feeding, transporting and boxing control system from the second HMI, switching to a manual mode for single step debugging, if the expected results can be achieved, indicating that the parameter calculation is correct, switching to an automatic control mode, and if the expected results can be achieved, recalculating the parameters until the results are correct;
3.4, when the feeding, transporting and boxing control system is in an automatic mode, if a signal is sent by the feeding material sensor, the control system carries out an automatic boxing process and simultaneously carries out alarm detection, and if an alarm is generated, the feeding, transporting and boxing control system is automatically stopped and alarms according to the alarm type; in the automatic control mode, the reset or stop operation can be carried out;
and 3.5, repeating the step 3.4 until the parameterization control is finished.
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